Page 1 This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it. NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
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Page 3: Before Reading This Manual
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details regarding the machine serial No. you will need to provide your Komatsu distributor, see "TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR (PAGE 1-8)".
Page 4: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed.
Page 5: Introduction
FOREWORD INTRODUCTION INTRODUCTION USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: Dozing Cutting into hard or frozen ground or ditching Felling trees, removing stumps Pushing Ripping For further details, see "WORK POSSIBLE USING BULLDOZER (PAGE 3-143)" and "RIPPER OPERATION (PAGE 3-145)".
Page 6: Visibility From Operator's Seat
FOREWORD INTRODUCTION VISIBILITY FROM OPERATOR'S SEAT The visibility standards (ISO 5006) for this machine require a view shown in the diagram below. PROXIMITY VISIBILITY The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown in the diagram below.
Page 7: Necessary Information
FOREWORD NECESSARY INFORMATION NECESSARY INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE Under the front of the console box on the right side of the operator's seat.
Page 8: Blade Serial No. Plate Position
FOREWORD NECESSARY INFORMATION BLADE SERIAL NO. PLATE POSITION This is located on the upper right of blade back surface. RIPPER SERIAL NO. PLATE POSITION This is located on the left side surface of ripper beam. ROPS, FOPS NO. PLATE POSITION This is at the top rear of the cab.
Page 9 FOREWORD NECESSARY INFORMATION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel Phone/Fax 1 - 8...
Page 10: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD BEFORE READING THIS MANUAL SAFETY INFORMATION INTRODUCTION USE OF MACHINE FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE VISIBILITY FROM OPERATOR'S SEAT NECESSARY INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE ENGINE SERIAL NO. PLATE AND POSITION BLADE SERIAL NO. PLATE POSITION RIPPER SERIAL NO.
Page 11 FOREWORD CONTENTS CAP WITH LOCK 3- 66 DOOR POCKET 3- 68 ASHTRAY 3- 68 CAR RADIO, HANDLING 3- 69 CAR STEREO, HANDLING 3- 74 HANDLING AIR CONDITIONER 3- 81 OPERATION 3- 95 CHECK BEFORE STARTING ENGINE, ADJUST 3- 95 STARTING ENGINE 3-116 OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-121...
Page 12 4- 10 WEAR PARTS LIST 4- 10 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 12 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 14 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 15 TORQUE LIST 4- 15...
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Page 15: Safety
SAFETY SAFETY SAFETY SAFETY LABEL POSITIONS OF SAFETY PICTOGRAMS SAFETY LABELS GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 11 PRECAUTIONS BEFORE STARTING OPERATION 2- 11 ENSURING SAFE OPERATION 2- 11 UNDERSTANDING THE MACHINE 2- 11 PREPARATIONS FOR SAFE OPERATION 2- 11 PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 11...
Page 16 SAFETY SAFETY PRECAUTIONS FOR OPERATION 2- 18 PRECAUTIONS FOR JOBSITE 2- 18 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 18 WORKING ON LOOSE GROUND 2- 18 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 19 ENSURE GOOD VISIBILITY 2- 19 CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 20 BEWARE OF ASBESTOS DUST 2- 20...
Page 17 SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE 2- 29 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 29 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 29 KEEP WORKPLACE CLEAN AND TIDY 2- 29 SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 29 ONLY AUTHORIZED PERSONNE 2- 29 APPOINT LEADER WHEN WORKING WITH OTHERS...
Page 18: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. 2 - 5...
Page 19: Positions Of Safety Pictograms
SAFETY SAFETY LABELS POSITIONS OF SAFETY PICTOGRAMS 2 - 6...
Page 20: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution for operation, inspection, and maintenance (09651-A0641) (2) Caution when traveling in reverse (09802-13000) (3) Warning for leaving operator's seat (09654-B0641) 2 - 7...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Warning for hot water hazard (09653-A0481) (5) Caution when adjusting track tension (09657-A0881) Safety label is attached to the back side of the inspection cover of the track frame. (6) Caution for handling accumulator (09659-A057B) 2 - 8...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (7) Caution for use of seat belt (195-98-12940) (8) Caution when handling cable (09808-A0881) (9) Caution against falling (09805-C0881) 2 - 9...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (10) Caution to stop engine when carrying out inspection and maintenance (09667-A0481) (11) Caution about going close when machine is moving (09806-B1683) (12) Prohibition of jump start (09842-A0481) 2 - 10...
Page 24: General Precautions Common To Operation And Maintenance
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 25: Keep Machine Clean
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE KEEP MACHINE CLEAN If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machine clean.
Page 26: Fire Prevention
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE FIRE PREVENTION ACTION IF FIRE OCCURS Turn the start switch OFF to stop the engine. Use the handrails and steps to get off the machine. Do not jump off the machine. There is the danger of falling and suffering serious injury. PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, antifreeze, or window washer fluid Do not bring any flame or fire close to flammable substances...
Page 27: Precautions When Getting On Or Off Machine
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Fire coming from piping Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire, serious personal injury or death.
Page 28: No Jumping On Or Off Machine
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE NO JUMPING ON OR OFF MACHINE Never jump on or off the machine. Never get on or off a moving machine. If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.
Page 29: 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 contact your Komatsu distributor for advice on the method of repair.
Page 30: Precautions When Running Engine Inside Building
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 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 machine must be operated inside a building or under ground, where the ventilation is poor, take steps to ensure that the engine exhaust gas is removed and that ample fresh air is brought in.
Page 31: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting operations, always check the following to confirm that there is no danger on the jobsite. When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
Page 32: Do Not Go Close To High-Voltage Cables
SAFETY PRECAUTIONS FOR OPERATION DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always do as follows.
Page 33: Starting Engine
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. STARTING ENGINE USE WARNING TAGS If there is any "DANGER! Do NOT operate!" warning tag displayed, it means that someone is carrying out inspection and maintenance of the machine.
Page 34: Inspection And Maintenance Before Starting Engine
SAFETY PRECAUTIONS FOR OPERATION INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is no problem with the operation of the machine. If this inspection is not carried out properly problems may occur with the operation of the machine, and there is danger that this may lead to serious personal injury or death.
Page 35: Starting With Booster Cables
SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. Always wear safety goggles and rubber gloves when starting the engine with booster cable.
Page 36: Operation
SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION If the checks before starting are not carried out properly, the machine will be unable to display its full performance, and there is also danger that it may lead to serious personal injury or death. When carrying out the checks, move the machine to a wide area where there are no obstructions, and pay careful attention to the surrounding area.
Page 37: Precautions When Traveling
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING Never turn the starting switch key to the OFF position when the machine is traveling. If the engine stops when the machine is traveling, it may become impossible to operate the steering, and this may cause serious personal injury or death.
Page 38: Precautions When Operating
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN OPERATING 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. The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of a slope.
Page 39: Parking Machine
SAFETY PRECAUTIONS FOR OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of landslides, falling rocks, or flooding. Lower the work equipment completely to the ground. When leaving the machine, set work equipment lock lever (1) and parking brake lever (2) to the LOCK position (L), and stop the engine.
Page 40: Transportation
The machine can be divided into parts for transportation, so when transporting the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 41: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING PRECAUTIONS WHEN TOWING Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or towing bar or in the method of towing a disabled machine may lead to serious personal injury or death. For towing, see "METHOD OF TOWING MACHINE (PAGE 3-177)".
Page 42: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE When carrying out inspection or maintenance, always attach the "DANGER! Do NOT operate!" warning tag to the work equipment control lever in the operator's cab to alert others that you are working on the machine.
Page 43: Stop Engine Before Carrying Out Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Lower the work equipment completely to the ground and stop the engine before performing any inspection and maintenance. Turn the starting switch to the ON position, operate the work equipment control lever to the RAISE and LOWER position 2 or 3 times repeatedly to release the remaining pressure in the hydraulic circuit, then set parking brake lever (1) and work...
Page 44: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows. One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 45: Precautions When Working On Top Of Machine
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN WORKING ON TOP OF MACHINE Clean up the machine to prevent falling off when performing maintenance, always do as follows. Do not spill oil or grease. Do not scatter the tools. Be careful at the time of the walk on the step. Remove mud and the oils and fats kind of the bottom of shoes.
Page 46: Precautions For Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE PRECAUTIONS WHEN WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.
Page 47: Precautions When Using Hammer
SAFETY PRECAUTIONS FOR MAINTENANCE Danger of sparks There is hazard that sparks will be generated, so always observe the following. Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools lying around near the battery.
Page 48: Precautions With High-Pressure Oil
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, please consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 49: Precautions With 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. It is necessary to disassemble the recoil spring assembly, always ask your Komatsu distributor to carry out the operation. 2 - 36...
Page 50: Handling Accumulator And Gas Spring
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. PRECAUTIONS WITH COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious personal injury caused by flying dust or particles.
Page 51: Periodic Replacement Of Safety Critical Parts
SAFETY PRECAUTIONS FOR MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To enable this machine to be used safely for a long period, always carry out periodic replacement of safety critical parts that have a particularly close relation to safety, such as hoses and the seatbelt. For details of the replacement of safety critical parts, see "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 4-16)".
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Page 53: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Blade Multi ripper Blade tilt cylinder Ripper lift cylinder Blade lift cylinder Sprocket (10) Track frame Track shoe (11) Frame Ripper tilt cylinder (12) Idler 3 - 2...
Page 54: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Parking brake lever Starting switch Work equipment lock lever (10) Brake pedal Cigarette lighter (11) Deceleration pedal Fuel control dial (12) Blade control lever Joystick (steering, directional and gear shift lever) (13) Horn switch Multi monitor...
Page 55 OPERATION GENERAL VIEW AA: Screen for standard BB: Screen with all lamps lighted up CC: Maintenance time warning screen Air conditioner switch (14) Service meter, clock Buzzer cancel switch (15) Reverse slow mode monitor Operating mode selector switch (16) ECO indicator Function switch (17) Fuel gauge...
Page 56: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MACHINE MONITOR AA: Screen for standard BB: Screen with all lamps lighted up...
Page 57 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR STARTING ENGINE WHEN SITUATION IS NORMAL When the starting switch is turned to the ON position, the opening screen GG is displayed. After the opening screen GG is displayed for 2 seconds, the screen switches to the check before starting screen After the check before starting screen DD is displayed for 2 seconds, the screen switches to the mode display screen.
Page 58 OPERATION EXPLANATION OF COMPONENTS STOPPING ENGINE WHEN SITUATION IS NORMAL When the starting switch is turned to the OFF position, ending screen JJ is displayed for 5 seconds, then the display goes out. 3 - 7...
Page 59 OPERATION EXPLANATION OF COMPONENTS IF THERE IS ABNORMALITY WHEN STARTING ENGINE If there is any abnormality when starting the engine, the check before starting screen DD changes to the maintenance interval warning screen CC, warning screen FF, or error screen EE. After displaying the check before starting screen DD for 2 seconds, the screen changes to the maintenance interval warning screen CC.
Page 60 OPERATION EXPLANATION OF COMPONENTS IF ANY ABNORMALITY OCCURS DURING OPERATION If any abnormality occurs during operation, the standard screen AA changes to warning screen FF-(1) or the error screen EE. After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen FF-(2). 3 - 9...
Page 61 OPERATION EXPLANATION OF COMPONENTS EMERGENCY MONITORS CAUTION If the monitor lights up red, stop the engine immediately or run at low idle, check applicable location, then perform necessary actions. These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up red and buzzer sounds, perform action immediately.
Page 62 OPERATION EXPLANATION OF COMPONENTS POWER TRAIN OIL TEMPERATURE MONITOR, HYDRAULIC OIL TEMPERATUREMONITOR This monitor (2) warns of an abnormal rise of power train oil temperature and hydraulic oil temperature. When the temperature becomes abnormally high, an abnormality symbol is displayed. When the symbol appears, stop the work and idle the engine until the monitor returns to the normal symbol, or simply stop the engine.
Page 63 OPERATION EXPLANATION OF COMPONENTS CAUTION MONITORS CAUTION If the warning monitor lights up red, stop operations as soon as possible and perform inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure. NOTICE Stop the machine on level ground and check the monitor.
Page 64 OPERATION EXPLANATION OF COMPONENTS BASIC CHECK MONITORS CAUTION These monitors do not guarantee the condition of the machine. Do not simply rely on the monitor when carrying out checks before starting (daily inspection). Always get off the machine and check each item directly. Displays basic items among the check before starting items that must be checked before starting the engine.
Page 65 For details of the method of checking the maintenance interval, see "MAINTENANCE MODE SELECTOR SWITCH (PAGE 3-28)". If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. 3 - 14...
Page 66 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION Engine pre-heating monitor Service meter, clock Operation mode monitor Air conditioner monitor Reverse slow mode monitor Message monitor (only machines equipped with Engine coolant temperature gauge KOMTRAX) Fuel gauge (10) ECO indicator Multi-gauge (11) Fan reverse monitor PILOT DISPLAY...
Page 67 OPERATION EXPLANATION OF COMPONENTS OPERATION MODE MONITOR This monitor (2) displays the operation mode. (P): Lights up when mode is set to power mode (E): Lights up when mode is set to economy mode The mode switches every time the operation mode selector switch is pressed.
Page 68 OPERATION EXPLANATION OF COMPONENTS GAUGES AND METER ENGINE COOLANT TEMPERATURE GAUGE This meter (4) shows the engine coolant temperature. During normal operations, the indicator should be in the green range. If the indicator enters the red range during operations, the overheat prevention system is actuated.
Page 69 OPERATION EXPLANATION OF COMPONENTS MULTI-GAUGE This gauge (6) displays a variety of items, but the following explanation describes the actuation for the power train oil temperature gauge and hydraulic oil temperature gauge. The indicator should be in the green range during operations. If the indicator enters the red range (A) during operation, it means that the oil temperature is too high.
Page 70 OPERATION EXPLANATION OF COMPONENTS SERVICE METER, CLOCK This meter (7) shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even if the machine is not moving. The service meter advances 1 for every hour that the machine is working, regardless of the engine speed.
Page 71 Monitor off: Air conditioner OFF MESSAGE MONITOR (ONLY MACHINES EQUIPPED WITH KOMTRAX) This monitor (9) lights up when there is a message from Komatsu. Press function switch F6 on the user menu to display the message. Lighted up green: There is unread message...
Page 72 OPERATION EXPLANATION OF COMPONENTS MONITOR SWITCHES PORTION Operating mode switch Buzzer cancel switch Gear shift mode selector switch Function switches Customize switch Air conditioner switch Customize memory switch OPERATING MODE SELECTOR SWITCH This switch (1) selects an engine operation mode. P mode is the normal working mode.
Page 73 OPERATION EXPLANATION OF COMPONENTS GEAR SHIFT MODE SELECTOR SWITCH This switch (2) switches the gear shift mode to automatic shift mode and manual shift mode. In the automatic shift mode, the transmission shifts up automatically to the maximum set speed range, and shifts down according to the load.
Page 74 OPERATION EXPLANATION OF COMPONENTS CUSTOMIZE MEMORY SWITCH CAUTION To ensure safety, always stop the machine before changing the mode. With this switch (4) the items set for up to 5 people using the customize function can be saved, and it is possible to recall the settings the next time the machine is used.
Page 75 OPERATION EXPLANATION OF COMPONENTS BUZZER CANCEL SWITCH When this switch (5) is pressed, the warning buzzer for the abnormal warning item stops. FUNCTION SWITCHES Function switches (6) consist of 6 switches (F1 to F6). The function of each switch differs according to the content of each screen.
Page 76 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH The air conditioner switches (7) consist of 9 switches. For explanation of each switch, see "HANDLING AIR CONDITIONER (PAGE 3-81)". 3 - 25...
Page 77 OPERATION EXPLANATION OF COMPONENTS HANDLING FUNCTION SWITCHES The function switches (A) at the bottom of the monitor display consist of 6 switches (F1 - F6). The function of each switch differs according to the content of each screen. The function of switches (A) on each screen can be confirmed by guidance icons (B) displayed on top of each switch.
Page 78 OPERATION EXPLANATION OF COMPONENTS SERVICE METER/CLOCK DISPLAY SELECTOR SWITCH On the standard screen, it is possible to press switch F4 to switch the service meter and clock display at the top of the monitor display. When the time is being displayed, press switch F4 to switch to the service meter display.
Page 79 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE MODE SELECTOR SWITCH When switch F5 is pressed on the standard screen, the monitor display screen switches to the maintenance mode screen. The items on the maintenance display are as follows. Change engine oil Replace engine oil filter Replace fuel main filter 1000 Replace fuel pre-filter...
Page 80 If the time remaining until maintenance becomes 0 hours, the remaining time display is highlighted in red. If you want to change the setting for the maintenance interval, please consult your Komatsu distributor. 3 - 29...
Page 81 OPERATION EXPLANATION OF COMPONENTS OPERATIONS ON MAINTENANCE INTERVAL RESET SCREEN On the maintenance interval reset screen, it is possible to carry out the following operations. F5: Cancels reset, returns to maintenance list screen F6: Resets remaining time, returns to standard screen If no switch is operated for 30 seconds on the maintenance interval reset screen, the screen automatically returns to the standard screen.
Page 82 OPERATION EXPLANATION OF COMPONENTS USER MODE SELECTOR SWITCH When the switch F6 is pressed, the monitor display screen switches to the setting mode screen for the machine. On the User Menu screen, it is possible to carry out the following operations with switches F3 to F6.
Page 83 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following items can be set. a: Utility Screen b: Multi-gauge c: Screen Adjustment d: Time Adjustment e: Language Setting f: Message display g: Fan Reverse 3 - 32...
Page 84 OPERATION EXPLANATION OF COMPONENTS The operation to set a - g is as follows. UTILITY SCREEN When the utility graph is selected with switch F6, it becomes possible to select the Standard Display, Load Display, or Body Pitch Display. Use switches F3 or F4 to select the item, then press switch F6 to confirm.
Page 85 OPERATION EXPLANATION OF COMPONENTS STANDARD DISPLAY This selects the standard screen. LOAD DISPLAY The horizontal axis shows the time and the vertical axis shows the rim pull. In the same way as with the ECO gauge, we recommend that you use it in the green range.
Page 86 OPERATION EXPLANATION OF COMPONENTS MULTI-GAUGE With this monitor, it is possible to select the gauge that is displayed in the center. Use switches F3 or F4 to select the item, then press switch F6 to confirm. NO. Multi-gauge selection item Remarks P/L oil Temperature There is a caution lamp...
Page 87 OPERATION EXPLANATION OF COMPONENTS An approximate value indicated by the gauge is as follows. Engine oil pressure (1)0.0MPa (2)0.2MPa (3)0.3MPa (4)0.4MPa (5)0.5MPa (6)0.7MPa Engine speed (1)500rpm (2)1,000rpm (3)1,500rpm (4)2,000rpm (5)2,500rpm (6)3,000rpm Battery voltage (1)0V (2)17V (3)20V (4)25V (5)30V (6)31V Machine speed (1)0km/h (2)5km/h (3)10km/h...
Page 88 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Drawbar pull (1)0W (2)0.2W (3)0.4W (4)0.6W (5)0.8W (6)1.0W Hydraulic pressure (1)0MPa (2)10MPa (3)20MPa (4)30MPa (5)40MPa (6)50MPa 3 - 37...
Page 89 OPERATION EXPLANATION OF COMPONENTS ADJUSTING SCREEN 1. On the standard screen, press switch F6. Use this screen adjustment menu to adjust the brightness, contrast, and back light of the screen. 2. Select screen adjustment on the user menu, then press switch F6.
Page 90 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Select item to be adjusted (a) or (b) from the selection menu screen for screen adjustment, then press switch F6. The screen switches to the setting screen for the selected item. (a): Standard screen adjustment (b): Camera screen adjustment (only machines equipped with camera)
Page 91 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS On the screen for Items 1) and 2), it is possible to carry out the following operations with switches F2 to F6. F2: Resets all adjusted values to default value F3: Indicator of selected item moves 1 segment to left. F4: Indicator of selected item moves 1 segment to right.
Page 92 OPERATION EXPLANATION OF COMPONENTS CLOCK ADJUSTMENT On this clock adjustment menu, it is possible to change the setting of the clock displayed on the pilot monitor of the standard display. 1. On the standard screen, press switch F6. 3 - 41...
Page 93 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 2. Select "Clock Adjustment" on the user menu, then press switch F6. The screen switches to the time adjustment selection menu screen. The following three items can be changed. (a) Clock setting (b) 12/24 hour display mode (c) Daylight saving time 3 - 42...
Page 94 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. On the clock adjustment selection screen, it is possible to carry out the following operations with switches F3 to F6. Time Adjust the hour setting. 1) If "Time" (a) is not highlighted in yellow, press switch F6 to highlight "Time"...
Page 95 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 12h/24h Mode Choose either a 12-hour display (am/pm) or a 24-hour display. (b): 24-hour display (c): 12-hour display (am/pm) 1) If "12h/24h Mode" (a) is not highlighted in yellow, press switch F6 to highlight "12h/24h Mode" (a) in yellow. 2) Change the "12h/24h mode"...
Page 96 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Daylight Saving Time (Summer time) 1) If daylight saving time is turned ON (a), the clock display becomes 1 hour earlier. If daylight saving time is turned OFF (b), the clock display returns to the set time. The selected display mode is highlighted in green.
Page 97 OPERATION EXPLANATION OF COMPONENTS LANGUAGE SELECTION On this language selection menu, it is possible to select the language used on the monitor display. The languages that can be selected are as follows. Japanese, English, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish 1.
Page 98 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Select the language to use for the display, then press switch F6. The screen display changes to the selected language. On the language selection screen, it is possible to carry out the following operations with switches F3 to F6.
Page 99 EXPLANATION OF COMPONENTS MESSAGE DISPLAY (Machines equipped with KOMTRAX) On machines equipped with KOMTRAX, it is possible to see the messages from your Komatsu distributor on this message display menu. REMARK At present, there is no territory where it is possible to the use the message service.
Page 100 OPERATION EXPLANATION OF COMPONENTS HYDRAULIC DRIVE FAN REVERSE MODE CAUTION In this mode, the fan cannot be rotated in reverse with the engine running. Keep parking brake lever and work equipment lock lever in the LOCK position. The machine cannot be driven while the fan is rotating in reverse. To release the cooling fan from a reverse rotation, turn the fuel control dial to the MIN position, then turn the starting switch to the OFF position and stop the engine.
Page 101 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS When this mode is selected, the screen in the diagram on the right appears. When screen (A) is being shown, press switch F6 to complete the preparations for rotating the fan in reverse. When screen (B) is being shown, the engine can be started.
Page 102: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting switch Cigarette lighter (24V) Horn switch Accessory socket (12V) Room lamp switch Front lamp switch Wiper switch Rear lamp switch STARTING SWITCH This switch (1) is used to start or stop the engine. (A): OFF position At this position, the starting switch key can be inserted and removed.
Page 103 OPERATION EXPLANATION OF COMPONENTS HORN SWITCH The horn sounds when the button (2) at the rear of the blade control lever at the right side of the operator's seat is pressed. ROOM LAMP SWITCH This (3) illuminates the room lamp. OFF position: Lamp is out ON position: Lamp lights up WIPER SWITCH...
Page 104 When installing the cab, check the colors and install the washer tank and each window washer hose correctly. When installing the cab, carry out the operation in accordance with the cab installation procedure manual held by your Komatsu distributor. 3 - 53...
Page 105 OPERATION EXPLANATION OF COMPONENTS CIGARETTE LIGHTER This lighter (5) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after a few seconds, so take it out to light your cigarette. By removing the cigarette lighter, the socket is available as a power source.
Page 106: Control Levers, Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS Fuel control dial Parking brake lever Joystick (steering, directional and gear shift lever) Work equipment lock lever Brake pedal Blade control lever Deceleration pedal Ripper control lever Pin puller control switch (if equipped) FUEL CONTROL DIAL Dial (1) is used to control the engine speed and output.
Page 107 OPERATION EXPLANATION OF COMPONENTS JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) (PCSS lever) Lever (2) is used to switch direction of travel and to steer the machine. REMARK PCCS: Palm command control system Forward-reverse shifting Position (a): FORWARD Position (b): REVERSE Position N: Neutral Move to the front to drive forward;...
Page 108 OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING Do not place your foot on this pedal unnecessarily. Depress the pedal (3) to apply the right and left brakes. DECELERATOR PEDAL WARNING Do not rest your foot on the pedal if you are not using it. When passing over the top of a slope or when dumping soil from a cliff, the load on the machine will suddenly be reduced and the travel speed will increase.
Page 109 OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT LOCK LEVER WARNING When standing up from the operator's seat, always move the work equipment lock lever securely to the LOCK position. If the blade control and ripper control levers are not locked and are touched by accident, it may lead to serious injury or damage.
Page 110 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER Lever (7) is used to operate the blade. Tiltdozer This lever is used to carry out the blade lift and tilt operations. Lifting control (a) RAISE (b) HOLD: Blade is stopped and held in this position. (c) LOWER (d) FLOAT: Blade will move freely according to external force.
Page 111 OPERATION EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER This lever (8) is used to operate the ripper. Lifting control (a) RAISE (b) HOLD: Ripper is stopped and held in the same position. (c) LOWER Tilting control (A) Digging angle reduced: Cutting angle (α) becomes smaller. (B) Digging angle increased: Cutting angle (α) becomes larger.
Page 112: Dust Indicator
OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR This is equipment to warn the operator that the air cleaner element has clogged up. For an element cleaning method, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-23)". 3 - 61...
Page 113: Fuse Box
OPERATION EXPLANATION OF COMPONENTS FUSE BOX NOTICE Before replacing a fuse, be sure to turn starting switch to the OFF position. Fuses protect the electrical equipment and wiring from burning out. If a fuse becomes corroded, or white powder can be seen, or a fuse is loose in the holder, replace the fuse. Replace a fuse with another of the same capacity.
Page 114 OPERATION EXPLANATION OF COMPONENTS CIRCUIT BREAKER If the engine does not start up when the starting switch is turned to the ON position, open up the battery cover and check the battery. If excessive current flows through the circuit breaker, it cuts off the electric circuit to prevent damage to the electrical components and wiring.
Page 115 Do not keep the circuit breaker reset button longer than necessary. If the starting motor does not work even when the circuit breaker has been reset, contact your Komatsu distributor.
Page 116 OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND NAME OF CIRCUIT FUSE BOX I (1) Fuse box fs1 Fuse Circuit capacity Permanently ON power source Backup alarm Main power source 1 Main power source 2 ACC signal (engine) (2) Fuse box fs2 Fuse Circuit capasity...
Page 117: Cap With Lock
OPERATION EXPLANATION OF COMPONENTS CAP WITH LOCK Lock-type caps are available for the radiator water filler, power train case oil filler cap, and hydraulic tank oil filler cap. For details of the locations of the caps with locks, see "LOCKING (PAGE 3-142)". OPENING AND CLOSING CAP WITH LOCK Use the starting switch key to open and close the locks on the caps except fuel tank cap.
Page 118 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPENING FUEL CAP The method of opening or closing the fuel tank cap is as follows. OPENING THE CAP 1. Raise lever (1) in the (a) direction. 2. When lever (1) is turned in the (c) direction (counterclockwise) by approx 35°, it stops at the stopper, and the cap can be opened.
Page 119: Door Pocket
OPERATION EXPLANATION OF COMPONENTS DOOR POCKET These are inside the left and right doors and can be used for keeping small objects. Do not put heavy objects such as tools in the pockets. If the pocket is dirty, turn 2 bolts (1), remove the pocket, and wash it in water.
Page 120: Car Radio, Handling
OPERATION EXPLANATION OF COMPONENTS CAR RADIO, HANDLING EXPLANATION OF COMPONENTS Power switch, volume knob Seek button (SEEK) Tone control knob Tuning button Display Preset station buttons Display selector button (CLOCK) FM/AM selector button (BAND) Station selector button (AST) POWER SWITCH, VOLUME KNOB When this knob (1) is turned clockwise from the OFF position, a click is heard and the power is turned on.
Page 121 OPERATION EXPLANATION OF COMPONENTS SEEK BUTTON (SEEK) When this button (6) is pressed, it automatically searches for stations that can be received. When it finds a station that can be received, it stops. TUNING BUTTON ∨ ∧ When the part of this button (7) is pressed, the frequency goes up; when the part of this button (7) is pressed, the frequency goes down.
Page 122 OPERATION EXPLANATION OF COMPONENTS METHOD OF USE METHOD OF LISTENING TO RADIO 1. Turn the starting switch to the ON position (B), then turn radio power switch (1) ON. 2. Use BAND button (9) to select AM or FM. 3. Select the channel with PRESET STATION button (8) or TUNE button (7).
Page 123 OPERATION EXPLANATION OF COMPONENTS METHOD OF PRESETTING 1. Select the desired preset station. Use BAND button (9) to select FM or AM, then use TUNE button (7) to select the frequency of the broadcasting station. 2. Decide one of preset buttons (8) to be used for the preset station, and keep it pressed for 2 seconds.
Page 124 OPERATION EXPLANATION OF COMPONENTS MONAURAL/STEREO AUTOMATIC SELECTION RECEPTION If the reception of the FM stereo broadcast is weak (when you are far from the broadcasting station or are surrounded by hills), the radio is automatically switched from stereo to monaural to reduce the interference. When the stereo broadcast becomes stronger, it automatically switches back to stereo broadcasting.
Page 125: Car Stereo, Handling
OPERATION EXPLANATION OF COMPONENTS CAR STEREO, HANDLING EXPLANATION OF COMPONENTS Power switch/volume Cassette door Auto-store/preset scan button Fast forward, rewind buttons Bass control knob (10) Preset buttons Treble control knob (11) Metal tape button Loudness button (12) Manual tuning buttons Time/radio display selector button (13) Seek tuning buttons...
Page 126 OPERATION EXPLANATION OF COMPONENTS POWER SWITCH/VOLUME Turn this knob (1) to the right until it clicks to turn the power on. Turn it further to increase the volume. AUTO-STORE/PRESET SCAN BUTTON Use this button (2) to actuate the preset scan and auto-store functions. Auto-store Each time this button is pressed for more than 2 seconds while in radio reception, this auto-store function automatically starts to search for the desired station within a receivable band, and memorize the frequency in the...
Page 127 OPERATION EXPLANATION OF COMPONENTS CASSETTE DOOR Set the cassette with the exposed portion of the tape on the right side and insert it through the cassette door (8). FAST FORWARD, REWIND BUTTONS These buttons (9) are used to fast-forward or rewind the tape. Fast forward/rewind If you press the button pointing in the same direction as the arrow indicating the direction of play, the tape will be fast forwarded;...
Page 128 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS To listen to a preset station, use band selector button (1) to select AM, FM1, or FM2, then press the preset switch number to listen to the desired station. It is possible to preset six AM stations and 12 FM stations (FM1: 6, FM2: 6).
Page 129 OPERATION EXPLANATION OF COMPONENTS MANUAL MEMORY BUTTON Select the station to be preset with manual tuning button (1) or seek tuning button (2), then keep button No.1 to button No.6 of button (3) pressed for 2 seconds while the frequency is being displayed to preset the station.
Page 130 OPERATION EXPLANATION OF COMPONENTS LISTENING TO CASSETTE TAPE 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Set the cassette with the exposed portion of the tape on the right side and push it past the cassette door. The tape will automatically start playing.
Page 131 If the sound cannot be heard, nothing is displayed, or any other problem occurs, turn off the power switch and ask your Komatsu distributor to make repairs without delay. Stow the antenna when traveling in places with low overhead clearance.
Page 132: Handling Air Conditioner
OPERATION EXPLANATION OF COMPONENTS HANDLING AIR CONDITIONER GENERAL LOCATIONS OF CONTROL PANEL OFF switch FRESH/RECIRC selector switch Fan switch Display monitor Temperature control switch Air conditioner switch Vent selector switch Sunlight sensor Auto switch OFF SWITCH Switch (1) is used to stop the fan and air conditioner. REMARK Even if this switch (1) is pressed, the monitor screen does not switch to the air conditioner adjustment screen.
Page 133 OPERATION EXPLANATION OF COMPONENTS FAN SWITCH Switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. Press the E switch to increase the air flow; press the R switc h to decrease the air flow. During auto operation, the air flow is automatically adjusted.
Page 134 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH Switch (3) is used to control temperature inside the cab. The temperature can be set between 18°C (64.4°F) and 32°C (89.6° Press the E switch to raise the set temperature; press the R switch to lower the set temperature.
Page 135 OPERATION EXPLANATION OF COMPONENTS VENT SELECTOR SWITCH Switch (4) is used to select the vents. When switch (4) is pressed, the display on monitor display (7) switches and air blows out from the vents displayed. During automatic operation, the vents are automatically selected.
Page 136 OPERATION EXPLANATION OF COMPONENTS AUTO SWITCH With switch (5), the air flow, vents, and air source (RECIRC/FRESH) are automatically selected according to the set temperature. Press switch (5), then use temperature control switch (3) to set the temperature, and run the air conditioner under automatic control.
Page 137 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH Switch (8) is used to turn the air conditioner (cooling, dehumidifying, heating) ON or OFF. Press air conditioner switch (8) when the fan is operating (when display (b) is shown on the display monitor). The air conditioner is switched ON and starts to work.
Page 138 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION The air conditioner can be operated automatically or manually. Select the method of operation as desired. AUTOMATIC OPERATION 1. Turn auto switch (5) ON. The monitors for the set temperature (a) and air flow (b) are also displayed.
Page 139 OPERATION EXPLANATION OF COMPONENTS STOPPING AUTOMATIC OPERATION Press OFF switch (1). Operation stops. MANUAL OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7). 2.
Page 140 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Press temperature setting switch (3) and adjust temperature inside the cab. 4. Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the display monitor changes according to the selection.
Page 141 OPERATION EXPLANATION OF COMPONENTS STOPPING MANUAL OPERATION Press OFF switch (1). Operation stops. OPERATION WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. 1.
Page 142 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Turn air conditioner switch (8) ON. 4. Adjust fan switch (2), temperature setting switch (3) and RECIRC/FRESH selector switch (6) to the desired positions. 3 - 91...
Page 143 OPERATION EXPLANATION OF COMPONENTS DEFROSTER OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7). 2. Press vent selector switch (4) and set vent display on the display monitor to (f) or (g) as shown in diagram on the right.
Page 144 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Press RECIRC/FRESH selector switch (6) and set it to take in fresh air. 4. Press temperature setting switch (3) and set temperature on the display (7) monitor to maximum heating. When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, turn air conditioner switch (8) ON.
Page 145 If any abnormality is detected in any equipment or sensor used on the air conditioner, "A/C Controller Error" is displayed on the air conditioner monitor screen. If "A/C Controller Error" is displayed, please ask your Komatsu distributor to carry out inspection and repair. 3 - 94...
Page 146: Operation
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Do not get on or off the machine from the rear. Using this position is dangerous because it is easy to slip and you cannot be seen from the operator's compartment.
Page 147 OPERATION OPERATION 7. Check for damage to handrail, loose bolts Repair any damage and tighten any loose bolts. 8. Check for damage to gauges, lamps on the instrument panel and loose bolts. Check for damage to the panel, gauges and lamps. If any problem is found, replace the parts. Clean off any dirt on the surface.
Page 148 Always check the items in this section before starting the engine each day. CHECK MACHINE MONITOR 1. Turn starting switch (1) to the ON position (B). 2. After the initial KOMATSU screen, check that the basic monitor screen is displayed and that the alarm buzzer sounds for approx. 2 seconds.
Page 149 OPERATION OPERATION CHECK COOLANT LEVEL, ADD COOLANT WARNING Normally, do not open the radiator cap. When checking the coolant level, check the sub-tank when the engine is cold. Do not remove the cap when the radiator coolant is hot. Boiling coolant may spurt out. After the coolant temperature goes down, turn the cap slowly to release the pressure, then remove it.
Page 150 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames near fuel because it is highly flammable and dangerous. 1.
Page 151 OPERATION OPERATION DRAIN WATER, SEDIMENT FROM FUEL TANK Prepare a container to catch the fuel that is drained. 1. Loosen drain valve (1) at the bottom of the fuel tank and drain the sediment and water accumulated at the bottom of the tank together with the fuel.
Page 152 OPERATION OPERATION CHECK ADDITIONAL WATER SEPARATOR, DRAIN WATER WARNING The water separator is a device to separate water mixed with fuel. When draining water, fuel is drained together. Therefore, never bring fire near the draining water. When draining water, prepare for a container used for draining oil and take care not to spill drained water. The drained water contains fuel and can catch fire.
Page 153 OPERATION OPERATION CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT 1. Open the side cover on the left side of the machine. The water separator forms one unit with the fuel filter and is at the bottom. 2. It is possible to judge the water level and amount of sediment by looking through transparent cap (2).
Page 154 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 155 OPERATION OPERATION CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL 1. Remove dipstick (G), and wipe the oil off with a cloth. 2. Fully insert dipstick (G) into filler pipe, then remove it. 3. Check that the oil level is between the H and L marks on dipstick (G).
Page 156 OPERATION OPERATION CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING When removing the oil filler cap, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap.
Page 157 OPERATION OPERATION CHECK DUST INDICATOR 1. Check for the yellow piston overlapping the red zone on the dust indicator (1). 2. If the yellow piston is overlapping the red zone, clean or replace the element immediately. For details of the method of cleaning the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-23)".
Page 158 Always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. CHECK THAT LAMPS LIGHT UP 1. Turn starting switch (1) to the ON position (B).
Page 159 OPERATION OPERATION CHECK HORN SOUND 1. Turn starting switch (1) to the ON position (B). 2. Push the horn switch and check that the horn sounds. 3 - 108...
Page 160 OPERATION OPERATION CHECK BACKUP ALARM SOUND 1. Turn starting switch to the ON position (B). 2. Set parking brake lever to the FREE position (F). 3. While depressing the brake pedal, set joystick to the REVERSE position. The buzzer must sound immediately. Buzzer will continue to sound until the joystick is moved to NEUTRAL or FORWARD position.
Page 161 OPERATION OPERATION ADJUSTMENT WARNING Make an adjustment of the operator's seat position before starting the machine operation or when an operator changes. Adjust the seat position the way the operator can fully depress the brake pedal with his or her back pressed against the backrest.
Page 162 OPERATION OPERATION USING SEAT BELT WARNING Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions. Replace any worn or damaged seat belt or the securing brackets. Even no problem can be seen with the belt, always replace the seatbelt once every three years. The date of manufacture is given on the rear side of the belt.
Page 163 OPERATION OPERATION ADJUST MIRROR WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously. Loosen nut (1) of the mirror and adjust the mirror to a position where it gives the best view from the operator's seat.
Page 164 OPERATION OPERATION ADJUST ARMREST The height of the armrest on the left and right sides of the operator's seat can be adjusted to 3 positions. After adjusting the operator's seat, adjust the armrest to a suitable height. ADJUST ARMREST (RIGHT) Armrest (1) on the right side of the operator's seat can be adjusted in 3 stages: up 30 mm (1.2 in), standard height (center), or down 25 mm (1.0 in).
Page 165 OPERATION OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check and make sure the work equipment lock lever (4) and parking brake lever (1) are secured in the LOCK position. If the control levers are not locked and they are touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious injury or death.
Page 166 OPERATION OPERATION OPERATION OPERATION REMARK The engine cannot be started if joystick (steering, directional, and gearshift lever) (2) is not in the N position. If joystick (steering, directional, and gearshift lever) (2) is in F or R, the letter P on display panel A will flash. 3.
Page 167: Starting Engine
OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 168 OPERATION OPERATION OPERATION OPERATION 3. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position (B). 3 - 117...
Page 169 OPERATION OPERATION STARTING IN COLD WEATHER WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
Page 170 OPERATION OPERATION OPERATION OPERATION 3. Check that engine pre-heating pilot lamp (3) on the monitor panel lights up. 4. Maintain the key in the on position until the pre-heating pilot lamp (3) goes off. 5. When preheating pilot lamp (3) goes off, turn the key of ignition switch (2) to the START position (C) to crank the engine.
Page 171 OPERATION OPERATION OPERATION OPERATION 6. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position (B). REMARK Immediately after starting the engine, run at idle. While running the engine, release the decelerator pedal and do not operate the work equipment.
Page 172: Operations And Checks After Starting Engine
BREAKING IN THE MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Page 173 (2) enters green range (A) - (C). (A) - (B): Red range (A) - (C): Green range (C) - (D): White range 3. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 122...
Page 174 If the power train oil temperature is not raised sufficiently, it will take longer to accelerate to the maximum speed. 5. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 123...
Page 175: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is stopped without allowing it to cool down, there is danger that the service life of various parts of the engine will be reduced. Except in emergencies, never stop the engine suddenly. If the engine overheats, do not stop it suddenly.
Page 176: Moving Machine
OPERATION OPERATION MOVING MACHINE WARNING Before moving the machine, check that the area around the machine is safe, and always sound the horn before moving. Do not allow anyone to enter the area around the machine. The rear of the machine is a blind spot, so be extremely careful when traveling in reverse.
Page 177 OPERATION OPERATION OPERATION OPERATION 3. Operate blade control lever (3) and ripper control lever (4) to the RAISE position, raise the blade 40 - 50 cm (15.8 - 19.7 in) from the ground, and raise the ripper to the maximum height. 4.
Page 178: Stopping Machine
OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, place the parking brake lever (1) in the LOCK position and insert blocks underneath the track shoes.
Page 179: Shifting Gear
OPERATION OPERATION SHIFTING GEAR The machine does not have to be stopped to shift gears. 1. Move steering, forward-reverse, gear shift lever (1) to the desired gear position to shift gears. GEAR SHIFTING The transmission speed will change when switch (a) or switch (b) is pushed.
Page 180 OPERATION OPERATION OUTLINE OF GEAR SHIFT MODES There are two gear shift modes: automatic shift mode and manual shift mode. Select the mode to match the use. Automatic shift mode (dozing mode) This is the mode used for general dozing operations. If a load is applied, the transmission automatically shifts down;...
Page 181 OPERATION OPERATION SETTING PRESET WITH SHIFT SWITCH OPERATION AT NEUTRAL Preset (speed range when moving machine off) and maximum speed range when traveling (automatic mode only) are set by operating the shift switch when the transmission is at neutral. Automatic mode Preset (speed range when moving machine off) and maximum speed range when traveling can be set.
Page 182 OPERATION OPERATION GEARSHIFTING OPERATION USING PRESET MODE FUNCTION Shift mode selection means that the selected speed range is displayed in the N position before starting. When the joystick is in the N position, if UP switch (a) or DOWN switch (b) is pressed, the shift mode selection can be carried out.
Page 183 OPERATION OPERATION SHIFTING SPEED RANGE BY OPERATING SWIFT SWITCH WHEN TRAVELING It is possible to operate the shift switch when traveling to change the maximum set speed range when traveling (automatic shift mode) or speed range used when traveling (manual shift mode). Automatic shift mode Changing maximum set speed range when traveling When traveling forward: Possible to change maximum speed...
Page 184 OPERATION OPERATION OPERATION OPERATION Manual shift mode Changing maximum speed range used when traveling When traveling forward: Possible to change speed range used to F1 - F3 When traveling in reverse: Possible to change speed range used to R1 - R3 up switch (a): Each time it is pressed, speed range used goes up one range down switch (b): Each time it is pressed, speed range used goes...
Page 185: Shifting Between Forward And Reverse
OPERATION OPERATION SHIFTING BETWEEN FORWARD AND REVERSE WARNING When switching between FORWARD and REVERSE, first check that the direction of travel is safe. CAUTION There is no need to stop the machine even when switching between FORWARD and REVERSE. To increase safety, operator comfort, and the life of the transmission, leave the engine running at full speed, and always depress the decelerator pedal to lower the engine speed.
Page 186 OPERATION OPERATION OPERATION OPERATION 4. Release decelerator pedal (1) and raise the engine speed. REMARK When the joystick is placed in REVERSE, the backup alarm will sound. 3 - 135...
Page 187: Steering Machine
OPERATION OPERATION STEERING MACHINE WARNING Avoid as much as possible turning the machine on a slope. The machine will tend to slip sideways. Particular care should be taken on soft or clay soil. Never make a pivot turn at high speed. NORMAL TURNING turn machine...
Page 188 OPERATION OPERATION TURNING WHILE DESCENDING A SLOPE TURNING GRADUALLY TO LEFT WHILE TRAVELING FORWARD If the joystick (1) is pushed forward and moved partially to the left (L), the machine turns gradually to the left. (Does not become cross steering) REMARK When making gradual turns to the right, push the joystick (1) forward, and move it partially to the right.
Page 189: Precautions For Operation
OPERATION OPERATION PRECAUTIONS FOR OPERATION PAY ATTENTION TO GAUGES If the red range of the power train oil temperature gauge lights up during operation, reduce the load and wait for the temperature to go down. PERMISSIBLE WATER DEPTH When operating in water, always keep top surface of the track frame above the surface of the water.
Page 190 OPERATION OPERATION PRECAUTIONS ON SLOPE BE CAREFUL OF FUEL LEVEL If the fuel level in the fuel tank becomes low when the machine is working on slopes, the engine may suck in air because of the angle of the machine or the swaying of the machine. This may make the engine stop, so be careful not to let the fuel level in the fuel tank become too low.
Page 191: Parking Machine
OPERATION OPERATION PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, place the parking brake lever (4) in the LOCK position and insert blocks underneath the track shoes.
Page 192 OPERATION OPERATION OPERATION OPERATION 3. Operate parking brake lever (4) to the LOCK (L) position. 4. Operate blade control lever (5) and ripper control lever (6) to LOWER position (c) and lower the blade and ripper to the ground. 5. Place blade control lever (5) and ripper control lever (6) at HOLD position (b).
Page 193: Check After Stopping Engine
OPERATION OPERATION CHECK AFTER STOPPING ENGINE 1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for any leakage of oil or coolant. If any problems are found, repair them. 2. Fill the fuel tank. 3.
Page 194: Work Possible Using Bulldozer
OPERATION OPERATION WORK POSSIBLE USING BULLDOZER If various attachments are used, it is possible to carry out operations in a wider range than listed below. DOZING A bulldozer digs and transports dirt in a forward direction. Slope excavation can always be most effectively carried out by proceeding from the top downward.
Page 195 OPERATION OPERATION CUTTING INTO HARD OR FROZEN GROUND OR DITCHING For digging and ditch excavation of hard or frozen ground, tilt the blade. Even hard ground can be dug effectively by a tilted or angled blade. FELLING TREES, REMOVING STUMPS NOTICE Do not uproot trees or stumps or fell trees by angling or tilting the blade.
Page 196: Ripper Operation
OPERATION OPERATION RIPPER OPERATION EFFECTIVE METHOD OF USE The most suitable digging angle for the shank is when the shank is perpendicular to the ground surface (angle at tip: 45° - 50°). For comparatively soft rock (seismic velocity: 1200m/s or below), it is also possible to carry out ripping with the shank tilted to the rear (maximum ripping angle).
Page 197 OPERATION OPERATION OPERATING ON SLOPES When using the variable ripper, adjust the length of the tilt cylinder to select dimension L. Slope face: Sloping face, such as on embankments 3 - 146...
Page 198 OPERATION OPERATION METHOD OF OPERATING PIN PULLER This operation is used only when a giant ripper is installed. 1. Stop the machine in a safe place and lower the shank to the ground. 2. Operate the pin puller controller switch to the "PULL OUT" position (1) and remove the mounting pin.
Page 199: Operating Method For Ripping Operations
OPERATION OPERATION OPERATING METHOD FOR RIPPING OPERATIONS BASIC OPERATING METHOD (1) Point in contact with ground (2) Insert point to specified depth (3) Ripping (4) Start raising ripper (5) Shank tilted back (6) Start lowering ripper TRACK OF RIPPER SHANK Carry out the ripping operation as follows, passing through the points shown in the diagram above.
Page 200 OPERATION OPERATION OPERATION OPERATION REMARK If the ripper is applied with the rear of the machine raised from the ground, the drawbar pull will be low, so the ripping efficiency will be reduced. If the ripping depth is kept constant, there will be no unevenness, and this will increase the efficiency of the dozing operation.
Page 201 OPERATION OPERATION OPERATION OPERATION REMARK In the case of the multi-shank ripper, carry out ripping at right angles to the slope face. Tilt back (MAX) Slope face Ripping base Cross ripping On jobsites with hard bedrock, for rocks and boulders which are impossible to break or dig up with one ripping pass, carry out the second ripping pass at right angles to the first ripping direction.
Page 202 OPERATION OPERATION OPERATION OPERATION 2. Operate the ripper lever to the TILT position and carry out ripping and digging. 3. If there are boulders which are impossible to break or dig up with the tilt operation, move forward slightly and tilt the shank back, then operate the tilt again and dig up the boulder.
Page 203 OPERATION OPERATION OPERATION OPERATION Do not carry out ripping for long periods with the shank tilted back (B). The tip of the point will wear to a round shape. Do not change the direction of travel during the ripping operation. This will cause breakage of the shank. When changing the direction of travel, remove the shanks from the ground before turning.
Page 204: Adjusting Posture Of Work Equipment
OPERATION OPERATION ADJUSTING POSTURE OF WORK EQUIPMENT WARNING When adjusting, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the work equipment lock lever. BLADE ADJUSTMENT TILTING THE TILTDOZER NOTICE...
Page 205 OPERATION OPERATION ADJUSTING BRACE WARNING If maintenance is carried out with the engine running, always have one worker sitting in the operator's seat while another worker carries out the maintenance. Both workers must mutually confirm the safety during the operation. Adjustment can be carried out more easily if the engine is started, the inching operation used to carry out tilting to the left and right, and the blade shaken up and down while turning the brace handle...
Page 206 OPERATION OPERATION METHOD OF ANGLING BLADE Angledozers only WARNING When adjusting the amount of angling, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the work equipment lock lever. Be careful when removing arm (2).
Page 207 OPERATION OPERATION OPERATION OPERATION REMARK When assembling a C-frame to an angledozer, adjust the length of arm (2) and brace (3) so that clearance S of center joint (4) is 20 mm (0.8 in). 3 - 156...
Page 208 OPERATION OPERATION ADJUSTING TILT AMOUNT (Angledozer, tiltdozer) WARNING When adjusting the amount of tilt, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the work equipment lock lever. ANGLEDOZER NOTICE The maximum amount of tilt is 400 mm (15.8 in).
Page 209 OPERATION OPERATION OPERATION OPERATION 3. Tighten set bolt (1). NOTICE The standard distance between the joints of the brace ( ) is 1292 mm (4 ft 3 in), but make sure that the maximum tilt does not exceed 400 mm (15.8 in). If the tilt exceeds 400 mm (15.8 in), there will be excessive force brought to bear on the parts, so do not use with a tilt of more than 400 mm (15.8 in).
Page 210 OPERATION OPERATION ADJUST ANGLE OF BLADE EDGE (Angledozer, tiltdozer) WARNING It is dangerous if the work equipment moves by mistake when adjusting angle of the blade edge. Set the work equipment in a stable condition, then stop the engine and lock the work equipment securely with the work equipment lock lever. Adjust the angle (θ) of the blade edge to match the type of soil.
Page 211: Tips For Longer Undercarriage Life
Select the track shoe that best suits the type of soil to be encountered in service. Consult your Komatsu distributor when selecting track shoes. Do not allow shoe slipage to occur during operation. If slipage occurs, reduce load to the blade until slipping stops.
Page 212 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. Perform periodical inspection and contact the Komatsu distributor in your area when machine has approached repairable limits and reversing limits.
Page 213 OPERATION OPERATION MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 1. Measure the height (dimension C) of the link tread as shown in the diagram. 2. Stop machine at position where link tread, whose size C has been measured completely, contacts roller tread. Then measure size B.
Page 214: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. LOADING, UNLOADING WORK WARNING Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely loaded and unloaded. If the ramp sags appreciably, reinforce it with blocks, etc.
Page 215 OPERATION TRANSPORTATION SECURING MACHINE NOTICE Stow the antenna away. Load the machine onto a trailer as follows: 1. Lower the work equipment slowly. (When transporting with work equipment installed) 2. Set the work equipment lock lever to the LOCK position (L) securely.
Page 216 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 5. Fix the machine as explained below so that it will not move during transportation. In particular, fix the machine securely to prevent it from slipping sideways. 1) Put blocks (1) in front and behind the track shoes of both sides.
Page 217 OPERATION TRANSPORTATION UNLOADING 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving. Set left and right ramps (2) parallel to each other and equally spaced to the left and right of center (3) of the trailer.
Page 218: Method Of Lifting Machine
The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. When lifting the machine, stop it on a level place, then observe the following procedure.
Page 219: Precautions For Transportation
OPERATION OPERATION TRANSPORTATION TRANSPORTATION NOTICE Use protectors to prevent the wire rope from being cut on sharp corners and to prevent the wire rope from cutting into the machine bodywork. When using a spreader bar, select an ample width to prevent contact with the machine.
Page 220: Removal Of Cab
OPERATION TRANSPORTATION REMOVAL OF CAB If it is necessary to remove the cab for transportation, disconnect the washer hose (1) and the cab power supply wiring (2), washer motor wiring (3), dashboard wiring harnesses (4), GPS wiring (5) (if equipped), Orbcomm wiring (6) (if equipped) from the connector before removing the cab.
Page 221 Orbcomm x 1 (if equipped)) from the socket. 3. When removing the cab, carry out the operation according to the cab installation manual held by your Komatsu distributor. REMARK After removing, cover with vinyl bag to prevent dirt or dust from entering the washer hose.
Page 222: Installation Of Cab
When installing the cab, check the colors and install the washer tank and each window washer hose correctly. When installing the cab, carry out the operation in accordance with the cab installation procedure manual held by your Komatsu distributor. Red-Right door Washer Blue-Left door...
Page 223: Cold Weather Operation
Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze. NOTICE Please use Komatsu genuine supercoolant (AF-NAC) for the coolant. As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine supercoolant.
Page 224 OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 225: After Completion Of Work
OPERATION COLD WEATHER OPERATION AFTER COMPLETION OF WORK WARNING Performing idle-running of the tracks is dangerous, stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions.
Page 226: Long-Term Storage
Place all control levers at the neutral position, set the work equipment lock lever and parking brake lever to the lock position, and set the fuel control dial to the low idling position. To prevent rust, fill with Komatsu genuine supercoolant (AF-NAC) to give a density of at least 30% for the engine coolant.
Page 227: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. Always watch the fuel level and be careful not to run out of fuel. If the engine has stopped because of lack of fuel, it is necessary to use the priming pump to bleed the air completely from the fuel circuit.
Page 228: Method Of Towing Machine
OPERATION TROUBLESHOOTING METHOD OF TOWING MACHINE WARNING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.
Page 229: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 230 OPERATION TROUBLESHOOTING PRECAUTIONS WHEN CHARGING BATTERY When the charging the battery, if the battery is mistakenly handled, there is danger of explosion. Follow the precautions in "IF BATTERY IS DISCHARGED (PAGE 3-178)" and the instructions given in the charger manual, and always do as follows.
Page 231 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows. PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, wear safety glasses and rubber gloves.
Page 232 OPERATION TROUBLESHOOTING STARTING THE ENGINE WARNING Always check that the work equipment lock lever and Parking brake lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are in the HOLD or NEUTRAL position. 1.
Page 233: Other Trouble
TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Defective wiring...
Page 234 Automatic functions stop, some functions stop, but operation is possible Inspect after completing operations Ask your Komatsu distributor to carry out repairs After user action to stop engine, operations are possible without limit functions when engine is restarted.
Page 235 OPERATION TROUBLESHOOTING CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Machine does not stop even when...
Page 236 OPERATION TROUBLESHOOTING ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lack of oil in oil pan (air being Add oil to specified level.
Page 237 REMARK If no point of contact telephone number has been registered, no telephone number is displayed. It is necessary to register the telephone number, please ask your Komatsu distributor to carry out the registration. 3 - 186...
Page 238 4 - 1...
Page 239: Maintenance
Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: For lubrication of the machine, use the 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 240 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Page 241 MAINTENANCE GUIDES TO MAINTENANCE PRECAUTIONS WHEN OPENING AND CLOSING ENGINE SIDE COVER: When standing on track to open the engine side cover, adopt a standing position, hold the side cover with both thumbs, and open it slowly with your other fingers. When the side cover is open, do not open or close the cab.
Page 242: Outlines Of Service
When using H046-HM hydraulic oil, drain all the oil and fill with the specified amount of oil. Always use oil recommended by Komatsu. If any other oil is used, it will cause clogging of the filter. There is no problem if the new oil is mixed with the small amount of oil remaining in the piping and cylinders.
Page 243 2 years or 4000 hours. As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine supercoolant (AF-NAC). If you use another coolant, it may cause serious problems such as corrosion of the engine and parts of the cooling system that use light metals such as aluminum.
Page 244 MAINTENANCE OUTLINES OF SERVICE GREASE Grease is used to prevent seizure and noises at the joints. This construction equipment is used under heavy-duty conditions. Always use the recommended grease and follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 245 Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair methods.
Page 246: Outline Of Electric System
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 247: Wear Parts List
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 248 MAINTENANCE WEAR PARTS Weight Replacement Item Part No. Part Name Q'ty (kg(lb)) frequency 17A-71-45230 Cutting edge (left) 32.2 17A-71-45220 Cutting edge (right) 32.2 17A-71-45210 Cutting edge 78.5 17A-71-45712 End bit (left) Sigmadozer 17A-71-45722 End bit (right) 17A-71-12451 (Bolt) (34) 17M-71-21530 (Nut) (34) 01643-22460...
Page 249: Recommended Fuel, Coolant, And Lubricant
RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 250 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4 - 13...
Page 251: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30% and 68%. RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. 4 - 14...
Page 252: Standard Tightening Torques 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, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 253: Periodic Replacement Of Safety Critical Parts
As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. Safety critical parts for periodic replacement...
Page 254 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q'ty Replacement interval 21 Hose between PPC divider block and work equipment lock valve 22 Hose between the oil cooler bypass valve and hydraulic oil cooler 23 Hose between self pressure reducing valve and drain relay block 24 Hose between main control valve and drain relay block 25 Hose between fan motor and hydraulic tank Hose between self pressure reducing valve and work equipment lock...
Page 255: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) REPLACE POWER TRAIN OIL FILTER ELEMENT 4- 67 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER) 4- 71 CHANGE OIL IN FINAL DRIVE CASE...
Page 256 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 500 HOURS SERVICE REPLACE FUEL PRE-FILTER CARTRIDGE 4- 64 CHECK FOR LOOSE ROPSCAB MOUNT BOLTS 4- 66 REPLACE POWER TRAIN OIL FILTER ELEMENT 4- 67 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 68 EVERY 1000 HOURS SERVICE CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER,...
Page 257: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance only after the first 250 hours. Replace power train oil filter element Change oil in power train case, wash strainers (power train pump strainer, scavenging pump strainer) Change oil in final drive case CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT For details of the method of replacing or maintaining, see EVERY 500 HOURS, EVERY 1000 HOURS and EVERY...
Page 258: When Required
2 years or 4000 hours. As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine supercoolant (AF-NAC). If you use another coolant, it may cause serious problems such as corrosion of the engine and parts of the cooling system that use light metals such as aluminum.
Page 259 If it gets into your eyes, wash your eyes immediately with ample water, then consult a doctor for treatment. NOTICE Please use Komatsu genuine supercoolant (AF-NAC) for the coolant. As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine supercoolant.
Page 260: Check, Clean And Replace Air Cleaner Element
MAINTENANCE SERVICE PROCEDURE CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING Always wear protective glasses, dust mask, or other protective equipment. When removing the air cleaner element from the air cleaner body, it is dangerous to pull it out by force. When working at high places or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element.
Page 261 MAINTENANCE SERVICE PROCEDURE CLEANING OUTER ELEMENT NOTICE Before and after cleaning the element, do not leave or keep it in direct sunlight. 1. Remove 6 holders (2), then remove cover (3) and take out outer element (4). NOTICE Never remove the inner element (5). It will allow dirt to enter and cause failure of the engine.
Page 262 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE NOTICE If small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning and drying, replace the element. When cleaning the element, do not hit it or beat it against something. Do not use an element whose folds or gasket or seal are damaged.
Page 263 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE NOTICE When inserting the element, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (3) is assembled by force to hook (2), there is danger that the hook and air cleaner body may be damaged, so be careful when assembling.
Page 264 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. Use a brush or cloth to remove all the dirt stuck to cover (3) and the inside of air cleaner body (6). NOTICE The inner element must not be cleaned and used again. When replacing the outer element, replace the inner element at the same time.
Page 265: Check And Adjust Track Tension
Never loosen plug (1) more than 1 turn. 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 with the procedure given here, please contact your Komatsu distributor. 4 - 28...
Page 266 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. 1. Remove 2 bolts (3), then remove cover (2).
Page 267: Check And Tighten Track Shoe Bolts
The situation can be extremely dangerous when removing the track. When following the adjustment procedure above in "WHEN LOOSENING TENSION (PAGE 4-29)", if the track does not become loose, contact your Komatsu distributor for repairs. CHECK AND TIGHTEN TRACK SHOE BOLTS Track shoes may be broken, if they are used with loosened shoe bolts (1).
Page 268: Adjust Idler Clearance
MAINTENANCE SERVICE PROCEDURE ADJUST IDLER CLEARANCE The idler moves forward and backward under external pressure when this happens, side guide and guide plate become worn. As they become worn, there is side play in the idler, or the idler turns at an angle, causing the track to come off or resulting in uneven wear, so adjust as follows.
Page 269 MAINTENANCE SERVICE PROCEDURE ADJUSTING IN VERTICAL DIRECTION 1. To determine the amount of adjustment, measure clearance B, then subtract 2 mm and record the result (amount of adjustment). Example If clearance B = 5 mm (0.197 in): Amount of adjustment = 5 - 2 = 3 mm (0.118 in) 2.
Page 270: Reverse And Replace The End Bits And Cutting Edges
MAINTENANCE SERVICE PROCEDURE REVERSE AND REPLACE THE END BITS AND CUTTING EDGES WARNING It is dangerous if the work equipment moves by mistake when the cutting edges and end bits are being reversed or replaced. Set the work equipment in a stable condition, then stop the engine and lock the blade control lever securely with the work equipment lock lever.
Page 271 MAINTENANCE SERVICE PROCEDURE (Semi U-dozer, U-dozer, Angledozer) The symbols used in the work equipment column are as follows. A: Semi U-dozer B: U-dozer, Angledozer [Unit: mm (in)] Item Judgement standard Measurement Work Standard Permissibl position equipment dimension e limit Height of outside 315 (12.4") 235 (9.25") of end bit 540 (21.3") 440 (17.3")
Page 272: Clean And Check Radiator Fins, Oil Cooler Fins, Aftercooler Fins
MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 2) When installing end bit (4), put top face (5) of the end bit in tight contact with stopper (6), then tighten the bolt. 6. After several hours of running, retourque the nuts. CLEAN AND CHECK RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS Carry out this procedure if there is any mud or dirt stuck to the radiator or oil cooler.
Page 273 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE REMARK When the engine is running, even if the fan rotation selector switch is operated, the direction of rotation of the fan will not change. The screenshot on the right is displayed to inform the operator that the direction of rotation of the fan has not changed.
Page 274 MAINTENANCE SERVICE PROCEDURE CLEAN RADIATOR FINS 1. Remove bolts (1) at the four corners of the radiator grill, then open radiator grill (2). 2. Clean the radiator fins clogged with mud, dust and leaves with compressed air. Steam or water may be used instead of compressed air.
Page 275: Clean, Check Air Conditioner Condenser Fins
MAINTENANCE SERVICE PROCEDURE CLEAN AFTERCOOLER FINS 1. Open the engine side cover on the right side of the machine. 2. Blow off dirt, dust and dry leaf shreds that clog the after-cooler fins, with compressed air. Steam or water may well be used for this purpose instead of compressed air.
Page 276: Inspection Of Additional Water Separator And Cleaning Of Casing Interior
MAINTENANCE SERVICE PROCEDURE INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASING INTERIOR WARNING When draining fuel from the water separator, prepare for a container used for catching drained oil and take care not to spill fuel. Spilt fuel can cause fire, so wipe it off completely. Fuel can pose danger as it is flammable.
Page 277 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. Loosen ring nut (6) to remove casing (7). 8. Remove screen (8) from the water separator table, pulling the screen out downward. 9. Wash screen (8) with clean fuel. At that time, also check it for damage and if any, replace it with a new one.
Page 278: Clean Hydraulic Tank Breather And Fuel Tank Breather
MAINTENANCE SERVICE PROCEDURE CLEAN STEERING CLUTCH CASE BREATHER Remove the breather, then wash it in clean diesel oil or flushing oil to rinse the dirt out from inside. Power train case breather (1 place) Remove external cover (2) at the bottom right of the cab. Breather (1) is installed to the right of the window (rear right of the machine).
Page 279: Replace Air Conditioner Belt
MAINTENANCE SERVICE PROCEDURE REPLACE AIR CONDITIONER BELT 1. Loosen 4 bolts (1) and jack bolt (2), then move compressor (3) to the side. 2. Replace the V-belt. When adjusting the V-belt, do not push the compressor directly with the bar. Use jack bolt (2). 3.
Page 280: Check Undercarriage Oil
2. If no oil comes out even when seal bolt is removed, the oil level is low. Contact your Komatsu distributor for repairs. REMARK If the side cover is not removed, seal bolt (1) at the idler portion cannot be seen.
Page 281: Clean Air Conditioner Air Filter (Fresh/Recirc Filter)
MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) Clean the air conditioner air filter if it becomes clogged or if there is dirt or oil stuck to it. 1. Loosen nut (1) located on the machine's rear left and remove the outer air filter by pulling handle (2).
Page 282: Check And Adjust Air Conditioner
MAINTENANCE SERVICE PROCEDURE CHECK AND ADJUST AIR CONDITIONER CHECK TENSION OF COMPRESSOR BELT If the driving belt slackens, it is likely to slip, lowering the cooling efficiency. Depress the mid point between drive pulley (1) and compressor pulley (2) with a thumb (approx. 58.8 N {6 kg}) every now and then to make sure that deflection amount (A) is approx.
Page 283: Lubricate Door Hinge
MAINTENANCE SERVICE PROCEDURE LUBRICATE DOOR HINGE If the door makes a squeaking noise when it is opened or closed, spray lubricant in through the split in the hinge bushing. If the bushing is worn, replace the hinge. CHECK DOOR LATCH WARNING It is quite dangerous if the machine suddenly starts to move during the inspection work.
Page 284: Replace Door Damper
MAINTENANCE SERVICE PROCEDURE REPLACE DOOR DAMPER If depth (A) of the groove of door damper rubber (1) is less than 2 mm (0.08 in), replace the damper. There are 4 dampers: 1 each at the top and bottom on the left and right doors.
Page 285: Replace Wiper Blade
MAINTENANCE SERVICE PROCEDURE REPLACE WIPER BLADE If the blade is damaged, it will not wipe the window clean, so replace the blade. REPLACEMENT FRONT, REAR WIPER 1. It is hooked at portion (A), so move the blade in the direction of the arrow to remove it.
Page 286: Bleeding Air In Hydraulic System
MAINTENANCE SERVICE PROCEDURE BLEEDING AIR IN HYDRAULIC SYSTEM See "OPERATIONS AND CHECKS AFTER STARTING ENGINE (PAGE 3-121)". Since the engine must be started and the blade must be operated, see OPERATION. NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing.
Page 287: Bleed Air From Fuel Circuit
MAINTENANCE SERVICE PROCEDURE BLEED AIR FROM FUEL CIRCUIT This machine is equipped with an electric priming pump to bleed the air from the fuel circuit. In the following cases, use the procedure below to bleed the air. When fuel filter has been replaced When engine has run out of fuel When starting the engine for the first time after replacing the supply pump or modifying the piping or any other parts...
Page 288 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. Operate switch (3) of the electric priming pump to the ON position. Lamp (4) will flash and the electric priming pump will start. REMARK The electric priming pump switch has a built-in timer, and this actuates and stops the pump automatically. While the lamp is flashing, the electric priming pump will stop, but this does not indicate any abnormality.
Page 289: Lubricating
MAINTENANCE SERVICE PROCEDURE LUBRICATING 1. Lower the work equipment to the ground, then stop the engine. 2. Remove the right and left foot rest. 3. Using a grease pump, pump in grease through the grease fittings shown by arrows. 4. After greasing, wipe off any old grease that was pushed out. Fuel control (2 places) Brake pedal (2 places) 4 - 52...
Page 290: Check Electrical Intake Air Heater
MAINTENANCE SERVICE PROCEDURE CHECK ELECTRICAL INTAKE AIR HEATER Check before the cold season starts (once a year). Remove the electric heater from the engine intake manifold and check for wire disconnections and dirt clinging to When checking and installing the electric heater, replace its gasket with a new one. 4 - 53...
Page 291: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-97)". Check machine monitor Check coolant level, add coolant Check fuel level, add fuel Drain water, sediment from fuel tank Check additional water separator, drain water and sediment Check water separator, drain water and sediment Check oil level in engine oil pan, add oil Check oil level in power train case, add oil...
Page 292: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE LUBRICATING 1. Lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3. After greasing, wipe off any old grease that was pushed out. Greasing equalizer bar side pins (2 places) Left and right sides of machine: 1 places each 1) Remove all soil and mud from the top of track frame and...
Page 293 MAINTENANCE SERVICE PROCEDURE Semi U-dozer Lift cylinder support yoke (4 places) Tilt cylinder ball joint (1 place) Lift cylinder support shaft (2 places) Pitch cylinder ball joint (1 place) Blade arm (1 place) 4 - 56...
Page 294 MAINTENANCE SERVICE PROCEDURE Angledozer Lift cylinder support yoke (4 places) Tilt brace screw (2 places) Lift cylinder support shaft (2 places) Ripper (1) Tilt cylinder bottom pin (1 place) (2) Lift cylinder bottom pin (1 place) (3) Tilt cylinder rod end pin (1 place) (4) Lift cylinder rod end pin (1 place) (5) Arm pin (front) (2 places) (6) Arm pin (rear) (2 places)
Page 295: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. 1. Stop the machine so that drain plug (1) is at the bottom. 2.
Page 296: Check Level Of Battery Electrolyte
MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this procedure before operating the machine. WARNING Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion. The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near the battery.
Page 297 If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 60...
Page 298 Neutralize the removed electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your battery maker. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 299: Check Alternator Drive Belt Tension, Adjust
V-groove. If any abnormality is found, ask your Komatsu distributor for replacement of the pulley. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.
Page 300: Check Brake Performance
SERVICE PROCEDURE CHECK BRAKE PERFORMANCE WARNING If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately. NOTICE Do not place the joystick in the 1st speed position. Otherwise, it will cause damage to the machine.
Page 301: Every 500 Hours Service
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 302 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. Remove seal (4) from transparent cap (3), then clean the cap. If transparent cap (3) is damaged, replace it with a new part. 5. Coat new seal (4) with clean fuel or oil, then install it to transparent cap (3).
Page 303: Check For Loose Ropscab Mount Bolts
MAINTENANCE SERVICE PROCEDURE CHECK FOR LOOSE ROPSCAB MOUNT BOLTS Check that there are no loose or damaged bolts. METHOD OF TIGHTENING MOUNT BOLT 1. First, tighten bolts (1) - (21) to a tightening torque of 294 ± 29.4 Nm. The order for tightening is as shown in the diagram.
Page 304: Replace Power Train Oil Filter Element
2. Remove mounting bolt (4) of filter (3), then remove cover (5). 3. Take out element. 4. Clean the removed parts and the inside of the case, then install a new element. Use Komatsu genuine element. 5. Install cover (2) and tighten bolt (1). 4 - 67...
Page 305: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING The oil is at high temperature after the engine has been operated, so never change the oil immediately after finishing operations. Wait for the oil to cool down before changing it. Oil replacement amount: 37 liters (9.78 US gal) Prepare a socket wrench and filter wrench.
Page 306 Be careful not to loosen the drain valve too much and deform the stopper pin inside the valve. 4. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 5. Tighten drain plug (P) and drain valve (2).
Page 307 MAINTENANCE SERVICE PROCEDURE 8. When installing, bring the packing face into contact with the filter holder, then tighten a further 3/4 - 1 turn. When using a filter wrench to tighten, be extremely careful not to damage or dent the filter. 9.
Page 308: Every 1000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 250 and 500 hours service should be carried out at the same time. CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER) WARNING The oil is at high temperature immediately after operations, so wait for the temperature to go down before starting the operation.
Page 309 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 2. Remove inspection cover (3) of the undercover on the bottom rear of the machine as follows. 1) Remove 2 bolts (4) on the machine front end. 2) Hold down cover (3) and remove 2 bolts (5) on the machine rear end gradually.
Page 310: Change Oil In Final Drive Case
MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 11. Replace the power train oil filter element. For details, see "REPLACE POWER TRAIN OIL FILTER ELEMENT (PAGE 4-67)". 12. Refill the specified quantity of oil through oil filler (F). 13. After filling with oil, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL (PAGE 3-104)".
Page 311: Lubricate Universal Joint
3. Lower the cover gradually to open it. (F)Front of the machine CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS Please ask your Komatsu distributor to check the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. 4 - 74...
Page 312: Replace Elements Of Hydraulic Tank Breather And Fuel Tank Breather
MAINTENANCE SERVICE PROCEDURE REPLACE POWER TRAIN CASE BREATHER Remove the breather, replace it with a new part. Power train case breather (1 place) Remove external cover (2) at the bottom right of the cab. Breather (1) is installed to the right of the window (rear right of the machine).
Page 313: Replace Pilot Filter Element
MAINTENANCE SERVICE PROCEDURE REPLACE PILOT FILTER ELEMENT 1. Loosen slowly oil filler cap (F) on top of the hydraulic tank to eliminate the internal pressure in the hydraulic circuit. 2. Open the left side cover and loosen bolt (1) to take off cover (2). 3.
Page 314 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. After checking that the hydraulic oil temperature has gone down, turn filter case (3) to the left, remove it, then take out element (4). 5. Clean the removed parts, then install new element (4). Element (4) must be installed facing in the correct direction.
Page 315: Check, Clean Fuel Strainer
MAINTENANCE SERVICE PROCEDURE CHECK, CLEAN FUEL STRAINER 1. Tighten fuel supply valve (1) at the bottom of the fuel tank, remove cap (2), then wash the strainer and strainer case. The strainer forms one unit with the cap. 2. After checking and cleaning the strainer, set it in the case, then tighten the cap.
Page 316: Replace Corrosion Resistor Cartridge
4. Clean the filter holder, coat the seal surface of the new cartridge thinly with oil, then install the cartridge. Always use a genuine Komatsu part for the cartridge. 5. When installing the cartridge, bring the packing surface into contact with the seal surface of the filter holder, then tighten a further 2/3 times.
Page 317: Replace Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 318 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE NOTICE Do not fill the new filter cartridge with fuel. Remove cap (B) and install the filter cartridge. 4. Clean the filter holder, coat the packing surface of the new filter cartridge thinly with oil, then install the filter cartridge to the filter holder.
Page 319: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before changing the oil.
Page 320: Clean Engine Breather Element
CHECK ALTERNATOR, STARTING MOTOR The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspection and repairs. If the engine is started frequently, have this inspection carried out every 1000 hours.
Page 321: Change Oil In Damper Case, Clean Damper Breather
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER WARNING The oil is at high temperature immediately after the machine has been operated.Wait for the oil to cool down before carrying out maintenance. The undercover is heavy. Do not go directly under the cover when opening or closing it. When removing bolts (4), carry out the operation at the rear of the point immediately under the cover so that it is possible to escape at any time.
Page 322: Check Pivot Bearing Oil Level, Add Oil
MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3) Lower cover (2) gradually to open it. Drain plug (P) can be seen at the top. 3. Remove dipstick (G), then remove drain plug (P) and drain the oil. After draining the oil,tighten drain plug (P). 4.
Page 323: Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
Page 324 MAINTENANCE SERVICE PROCEDURE CHECKING FUNCTION OF ACCUMULATOR CAUTION When carrying out the inspection, check first that there is no person or obstacle in the surrounding area. Check the nitrogen gas charge pressure as follows. 1. Stop the machine on firm, level ground. 2.
Page 325 Please contact your Komatsu distributor for inspection. 8. This completes the inspection. After completing the inspection, set the work equipment lock lever to the LOCK position and turn the starting switch to the OFF position.
Page 326 MAINTENANCE SERVICE PROCEDURE METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT 1. Lower the work equipment to the ground. 2. Set the parking brake lever and work equipment lock lever to the LOCK position. Carry out Steps 3 - 5 within 15 seconds. When the engine is stopped, the pressure in the accumulator gradually goes down.
Page 327: Every 4000 Hours Service
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
Page 328: Check Water Pump
Check that there is no deformation of the surface of damper (1) and that there are no signs of leakage of damper oil from around the damper. If any abnormality is found, please ask your Komatsu distributor to carry out replacement. 4 - 91...
Page 329: Checking For Looseness Of High-Pressure Clamp, Hardening Of Rubber
(1) - (18) in the diagram on the next page and no hardening of any rubber parts. If any problem is found, the part must be replaced. In this case, please ask your Komatsu distributor to carry out the replacement.
Page 330: Checking For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
Check visually and touch by hand to check that there are no missing caps, no loose mounting bolts, and no hardening of any rubber parts. If any problem is found, the part must be replaced. In this case, please ask your Komatsu distributor to carry out the replacement. 4 - 93...
Page 331: Every 8000 Hours Service
Maintenance for every 250, 500, 1000, 2000, and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMPS Contact your Komatsu distributor to have the engine high-pressure clamps replaced. REPLACE FUEL SPLAY PREVENTION CAPS Contact your Komatsu distributor to have the fuel spray prevention cap replaced. 4 - 94...
Page 332 5 - 1...
Page 333: Specifications
Blade (semi U tiltdozer) kg (lb) 4,960 (10,937) Unit weight (including cylinder) Ripper unit weight kg (lb) 3,380 (7,453) Name of engine Komatsu SAA6D140E-5 diesel engine Engine horsepower kW (HP)/rpm 239 (320)/1,900 Overall length mm (ft in) 8,680 (28' 6") Overall height mm (ft in) 3,395 (11' 2")
Page 334 6 - 1...
Page 335: Attachments, Options
GENERAL PRECAUTIONS PRECAUTIONS RELATED TO SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distributor first.
Page 336: Introduction Of Attachments And Options
710 mm (28 in) Heavy-duty shoe width 610 mm (24 in) Heavy-duty shoe width 660 mm (26 in) Ripper point Cap with lock Headrest Various other optional parts are available, so please contact your Komatsu distributor. 6 - 3...
Page 337: Headrest, Handling
ATTACHMENTS, OPTIONS HEADREST, HANDLING HEADREST, HANDLING Use the headrest fully pushed in to the lowest position. 6 - 4...
Page 338: Procedure For Selecting Ripper Point
ATTACHMENTS, OPTIONS PROCEDURE FOR SELECTING RIPPER POINT PROCEDURE FOR SELECTING RIPPER POINT PROCEDURE FOR SELECTING RIPPER POINT REMARK A symmetrical ripper point is suited to a terrain of hard rocks because it recovers penetrability by turning the point after the penetrability drops due to its worn tip. Ripper points usually lose their hardness when they undergo intense heat generated by a contact with rocks during the use.
Page 339: Handling Machines Equipped With Komtrax
Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications.
Page 340: Index
INDEX INDEX <A> PRECAUTIONS BEFORE STARTING ADJUSTING POSTURE OF WORK OPERATION 2- 11 EQUIPMENT 3-153 PRECAUTIONS RELATED TO ASHTRAY 3- 68 ATTACHMENTS AND OPTIONS 2- 16 PRECAUTIONS RELATED TO <B> PROTECTIVE STRUCTURES 2- 16 BEFORE READING THIS MANUAL PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 14 <C>...
Page 341 INDEX METHOD OF LIFTING MACHINE 3-167 SAFETY INFORMATION MOVING MACHINE 3-125 SAFETY LABELS POSITIONS OF SAFETY <N> PICTOGRAMS NECESSARY INFORMATION SAFETY LABELS SERVICE PROCEDURE 4- 20 <O> CHECK BEFORE STARTING 4- 54 OPERATING METHOD FOR RIPPING EVERY 1000 HOURS SERVICE 4- 71 OPERATIONS 3-148...
Page 342 INDEX <W> WEAR PARTS 4- 10 WEAR PARTS LIST 4- 10 WORK POSSIBLE USING BULLDOZER 3-143 7 - 3...

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