Page 1 D85EX- 10250 SERIAL NUMBERS and up D85PX- 1109 NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages . If a foreign language manual is necessary , contact your local distributor for availability . WARNING Unsafe use of this machine may cause serious injury or Death.
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Page 3: Foreword
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
Page 4 FOREWORD FOREWORD 1 - 3...
Page 5 FOREWORD FOREWORD 1 - 4...
Page 6: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8: Introduction
BREAKING IN THE MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
Page 9: 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 10: Position Of Service Meter
FOREWORD NECESSARY INFORMATION POSITION OF SERVICE METER On top of the machine monitor 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 - 9...
Page 11: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE BREAKING IN THE MACHINE NECESSARY INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE ENGINE SERIAL NO. PLATE POSITION OF SERVICE METER TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SAFETY SAFETY SAFETY LABELS...
Page 12: Table Of Contents
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 10 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 11 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 12 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 13 TORQUE LIST...
Page 13: Table Of Contents
FOREWORD CONTENTS MAINTENANCE SCHEDULE CHART 4- 16 MAINTENANCE SCHEDULE CHART 4- 16 ADJUST INJECTOR 4- 18 SERVICE PROCEDURE 4- 19 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 19 WHEN REQUIRED 4- 20 CHECK BEFORE STARTING 4- 44 EVERY 250 HOURS SERVICE 4- 45 EVERY 500 HOURS SERVICE...
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Page 15: Safety
SAFETY SAFETY SAFETY Safety Labels Positions of Safety Pictograms Safety Labels General Precautions Safety Rules If Abnormalities are Found Clothing and Personal Protective Items Fire Extinguisher and First Aid Kit Safety Features Keep Machine Clean 2- 10 Inside Operator's Compartment 2- 10 Always Apply Lock when Leaving Operator's Seat 2- 10...
Page 16 SAFETY SAFETY Precautions for Operation 2- 17 Before Starting Engine 2- 17 Checks Before Starting Engine 2- 17 Precautions when Starting 2- 18 Precautions in Cold Areas 2- 18 Operation 2- 19 Checks Before Operation 2- 19 Precautions for Moving Machine Forward or in Reverse 2- 19 Precautions when Traveling 2- 20...
Page 17 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. POSITIONS OF SAFETY PICTOGRAMS...
Page 18: 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 - 5...
Page 19 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) Precautions for handling electric wires (09808-A0881) (7) Caution for engine running (09667-A0481) 2 - 6...
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (8) Caution for handling accumulator (09659-A057B) (9) Caution for approach when machine moving (09806-B1683) (10) ROPS (09620-B2000) (11) FOPS (09620-C2000) 2 - 7...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (12) Roll-over precautions (09805-C0881) (13) Jump start prohibited (09842-A0481) 2 - 8...
Page 22: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions in this manual when operating or performing maintenance on the machine. If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
Page 23: General Precautions
SAFETY GENERAL PRECAUTIONS KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes.
Page 24 SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the parts marked by arrow A in the diagrams when getting on or off the machine. Never use the parts marked by arrow B when getting on or off the machine.
Page 25 SAFETY GENERAL PRECAUTIONS PREVENTION OF BURNS Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 26: Specifications
If ROPS is deformed by falling objects or by rolling over, its strength lowers and its design functions cannot be maintained. In this case, be sure to ask your Komatsu distributor about repair method. Even when the ROPS is installed, if you do not fasten your seat belt securely, it cannot protect you properly. Always fasten your seat belt when operating the machine.
Page 27 Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 28 SAFETY GENERAL PRECAUTIONS 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 29 Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 16...
Page 30 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION BEFORE STARTING ENGINE If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Completely remove all flammable materials accumulated around the engine and battery, and remove any dirt from the windows, mirrors, handrails and steps.
Page 31: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN STARTING Start and operate the machine only while seated. 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. When starting the engine, sound the horn as a warning. Do not allow anyone apart from the operator to ride on the machine.
Page 32 SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of travel, steering and brake systems, and work equipment control system.
Page 33: Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING When traveling on flat ground, keep the work equipment 40 to 50 cm (16 to 20 in) high above the ground. When traveling on rough ground, travel at low speed and do not operate the steering suddenly.
Page 34 SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. When traveling on slops, keep the blade approxmately 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, quickly lower the blade to the ground to help the machine to stop.
Page 35 SAFETY PRECAUTIONS FOR OPERATION PARKING MACHINE Park the machine on level ground where there is no danger of falling rocks or landslides, or of flooding if the land is low, and lower the work equipment to the ground. If it is necessary to park the machine on a slope, set the blocks under the tracks to prevent the machine from moving, then dig the work equipment into the ground.
Page 36: Transportation
PRECAUTIONS FOR OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating 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 37 SAFETY PRECAUTIONS FOR OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. When the battery electrolyte is below LOWER LEVEL, don't either use or charge the battery. Otherwise, that may cause explosion.
Page 38: Battery
SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLE 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. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 39: Towing
If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic system, the brake works and the machine cannot move. To move the machine in this case, the oil pressure in the brake circuit must be heightened to the specified level with a special device. Ask your Komatsu distributor. 2 - 26...
Page 40 SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG Always attach the "DO NOT OPERATE" warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 41: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Stop 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 and stop the engine.
Page 42 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. 2 - 29...
Page 43 SAFETY PRECAUTIONS FOR MAINTENANCE PERSONNEL Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard. ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall.
Page 44 If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work. 2 - 31...
Page 45 Never touch the inside of the controller or the engine injector portion. If it is necessary to touch the inside of the controller or the engine injector portion, please contact your Komatsu distributor.
Page 46 SAFETY PRECAUTIONS FOR MAINTENANCE WASTE MATERIAL To prevent pollution, pay careful attention to the method of disposing of waste materials. Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes.
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Page 49: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Blade Sprocket Blade lift cylinder Track frame Frame ROPS guard Track shoe Ripper 3 - 2...
Page 50: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Parking brake lever (11) Rear lamp switch Work equipment lock lever (12) Fan rotation selector switch Cigarette lighter (13) Starting switch Fuel control dial (14) Information switch Joystick (15) Buzzer cancel switch (Steering, directional and gear shift lever) (16) Brake pedal...
Page 51 OPERATION GENERAL VIEW FRONT PANEL Engine coolant temperature gauge (11) Engine pre-heating pilot lamp Power train oil temperature gauge (12) Maintenance caution lamp Hydraulic oil temperature gauge (13) Warning lamp Fuel level gauge (14) Filter / oil change interval lamp Radiator coolant level monitor (15) Display panel A...
Page 52: 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. FRONT PANEL Check monitor group Meter group...
Page 53 OPERATION EXPLANATION OF COMPONENTS B: Caution monitor group (See "CAUTION MONITOR GROUP (PAGE 3-9)") CAUTION If the caution lamp for any of these items flashes, check and repair the appropriate item as soon as possible. These are items which need to be observed when the engine is running. If any problem occurs, the item needing immediate repair is displayed.
Page 54 Park the machine on level ground and then check the monitor lamps. Confirm that monitor lamps light up about 2 seconds after the starting switch is turned to the ON position. If any monitor lamp does not light, contact your Komatsu distributor to inspect and repair. REMARK When the starting switch is turned to the ON position, before starting the engine, the caution lamps flash for 2 seconds, the warning lamps light up for 2 seconds, and the alarm buzzer sounds for 2 seconds.
Page 55 OPERATION EXPLANATION OF COMPONENTS RADIATOR COOLANT LEVEL CAUTION LAMP This lamp (1) warns the operator that the level of the cooling water in the radiator has gone down. If the lamp flashes, check the level of the cooling water in the main radiator, and add water.
Page 56 Confirm that monitor lamps light up about 2 seconds after the starting switch is turned to the ON position. If any monitor lamp does not light, contact your Komatsu distributor to inspect and repair. These are items which need to be observed when the engine is running. If any problem occurs, the item needing immediate repair is displayed.
Page 57 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE CAUTION LAMP This lamp (2) lights up for approx. 30 seconds after the starting switch is turned to the ON position if the filter or oil replacement interval has been reached. After replacing the indicated filter or oil displayed on display panel B (multi-information), reset the interval.
Page 58 OPERATION EXPLANATION OF COMPONENTS EMERGENCY CAUTION ITEMS CAUTION If any of the caution lamps begins to flash, stop the engine or reduce the engine speed to low idle immediately and check the trouble spot for necessary actions. These items must be monitored when the engine is running. If there is any problem, the caution lamp for the location of the problem and warning lamp (A) flash, and the alarm buzzer sounds intermittently.
Page 59 OPERATION EXPLANATION OF COMPONENTS ENGINE OIL PRESSURE CAUTION LAMP This lamp (1) indicates low engine oil pressure. If the monitor lamp flashes, stop the engine and check it immediately. REMARK The alarm buzzer sounds, when the starting switch is turned to ON immediately after the engine oil has been changed.
Page 60 When the engine is stopped, turn that the starting switch to the ON position and check that the gauge or monitor for the engine water temperature gauge, power train oil temperature gauge, and fuel gauge light up. If they do not light up, please contact your Komatsu distributor for repairs. D(1)
Page 61 OPERATION EXPLANATION OF COMPONENTS ENGINE COOLANT TEMPERATURE GAUGE NOTICE If the coolant temperature gauge often enters red range (C), check the radiator for clogging. Gauge (1) indicates temperature of the engine coolant. If the temperature is normal during operation, green range (B) will light.
Page 62 OPERATION EXPLANATION OF COMPONENTS HYDRAULIC OIL TEMPERATURE GAUGE Gauge (3) indicates the hydraulic oil temperature. If the temperature is normal during operation, green range (B) will light. If red range (C) lights up during operation, move the fuel control dial to lower engine speed to approx.
Page 63 OPERATION EXPLANATION OF COMPONENTS ENGINE PRE-HEATING PILOT LAMP Lamp (5) indicates that engine is being pre-heated by the electrical heater during cold weather. The engine controller detects the coolant temperature and automatically actuates pre-heating in low temperatures when starting the engine. DISPLAY PANEL A (speed range display, engine speed) Meter (6) displays the transmission speed range being used on the machine and engine speed.
Page 64 OPERATION EXPLANATION OF COMPONENTS DISPLAY PANEL B (Multi-information) The top and bottom lines in display panel B (multi-information) display information related to the condition of the machine. The content of the display is divided into "OPERATING MODE" and "MAINTENANCE MODE". Use the buzzer cancel switch to switch between the operating mode and maintenance mode.
Page 65 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Maintenance mode This displays various types of information related to maintenance of the machine. The maintenance mode is displayed by continuing to turn the buzzer cancel switch in the direction for 2.5 seconds. For details, see "METHOD OF USING DISPLAY PANEL B (Multi-information) (PAGE 3-25)".
Page 66 OPERATION EXPLANATION OF COMPONENTS SWITCHES E(1) Starting switch E(5) Rear lamp switch E(2) Buzzer cancel switch E(6) Fan rotation selector switch E(3) Preset mode switch E(7) Information switch E(4) Front lamp switch E(8) Auto shift down switch STARTING SWITCH Switch (1) is used to start the engine. Key insertion-withdrawal position.
Page 67 OPERATION EXPLANATION OF COMPONENTS BUZZER CANCEL SWITCH This switch used operate control panel (multi-information) or to stop the alarm buzzer. When the switch is released, it returns automatically to the center position. When display panel B (multi-information) is in operation mode When the alarm buzzer is sounding, turn this switch to the left or right to stop the buzzer.
Page 68 OPERATION EXPLANATION OF COMPONENTS REAR LAMP SWITCH This switch (5) lights up when the rear lamp and panel lamp light (OFF) position: Lights out (ON) position: Lights on FAN ROTATION SELECTOR SWITCH This switch (6) is used to switch the direction of rotation of the cooling fan.
Page 69 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS REMARK If the engine is running, the direction of rotation of the fan will not change even when the fan rotation selector switch is operated. The fan operation confirmation lamp will flash to inform the operator that the direction of rotation of the fan has not changed.
Page 70 OPERATION EXPLANATION OF COMPONENTS LAMPS F(1) Warning lamp F(3) Fan operation confirmation lamp F(2) Filter/oil change interval lamp WARNING LAMP (Red) NOTICE If alarm buzzer sounds, stop work immediately and perform inspection and maintenance of the appropriate point. This lamp (1) flashes when the caution lamp flashes and when an action code is displayed on display panel B (multi-information).
Page 71 OPERATION EXPLANATION OF COMPONENTS FILTER/OIL CHANGE INTERVAL LAMP (Yellow) This lamp (2) lights up when the time for replacing the filter or oil is near. REMARK This lamp (2) lights up if there is less than 30 hours remaining until replacement, and flashes when the replacement interval has passed.
Page 72 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING DISPLAY PANEL B (Multi-information) To switch from the operation mode to the maintenance mode, turn the buzzer cancel switch to the position and hold it there for at least 2.5 seconds. The screen will switch to the maintenance mode.
Page 73 OPERATION EXPLANATION OF COMPONENTS METHOD OF SELECTING MODES 3 - 26...
Page 74 This function is only a guideline. If dirty oil or filters are found during daily maintenance, replace them immediately. If the controllers or monitor panel are replaced, the timer for this function will not work properly. Contact your Komatsu distributor for replacement.
Page 75 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS REMARK To return to the maintenance mode, operate the buzzer cancel switch to 3 - 28...
Page 76 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING PM CLINIC AUXILIARY MODE CAUTION When moving the work equipment or setting the transmission to the travel position for carrying out measurements, check carefully that the situation is safe. The PM clinic auxiliary mode displays the engine speed, hydraulic oil pressure, and other items on display panel B. Display panel B (Malti-information) displays the item on the top line (1) and the measured value on the bottom line (2).
Page 77 When any disconnection or short circuit in any sensor is detected, the location and fault code are displayed by a 6-digit code on display panel B (multi-information). When contacting your Komatsu distributor, inform your distributor of the code at the same time.
Page 78 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING USER ADJUST MODE With the user adjust mode, the brightness of the panel screen backlighting and the contrast of the liquid crystal panel can be changed, or the cooling fan can be set to maximum speed to clean the radiator when it is clogged. These are displayed on display panel B.
Page 79 OPERATION EXPLANATION OF COMPONENTS 2. Adjusting backlighting of display panel B (multi-information) 1) The diagram on the right is the mode for adjusting the brightness of the backlighting of the display panel B (multi-information). On the screen, operate the buzzer cancel switch to switch to the screen for adjusting the brightness.
Page 80 OPERATION EXPLANATION OF COMPONENTS 3. Adjusting contrast of liquid crystal display panel B (multi-information) 1) The diagram on the right is the mode for adjusting the contrast liquid crystal display panel (multi-information). On this screen, operate the buzzer cancel switch to to switch to the screen to adjust the contrast.
Page 81: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Fuel control dial Wiper switch Horn switch Cigarette lighter Room lamp switch Accessory socket FUEL CONTROL DIAL Dial (1) is used to control the engine speed and output. (a) Low idling position: Turn fully to the left (b) High idling position: Turn fully to the right REMARK To stop the engine, turn the starting switch to the OFF position.
Page 82 OPERATION EXPLANATION OF COMPONENTS ROOM LAMP SWITCH This (3) illuminates the room lamp. OFF position: Lamps are out ON position: Lamps light up WIPER SWITCH This (4) activates the wipers. The wiper switches are as follows: (LH) Left door (FF) Front window (RH) Right door (RR) Rear window (INT) Wiper intermittent operation switch...
Page 83 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Window washer only Keep the switch pressed to the OFF position to spray out water. Wiper intermittent operation switch If the wiper is operated with the switch at the ON position, the wiper will move once every four seconds.
Page 84 OPERATION EXPLANATION OF COMPONENTS CIGARETTE LIGHTER This (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. If the cigarette lighter is removed, the socket can be used as a power source.
Page 85: Control Levers, Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS Work equipment lock lever Brake pedal Parking brake lever Deceleration pedal Joystick (steering, directional and Blade control lever gear shift lever) Ripper control lever WORK EQUIPMENT LOCK LEVER WARNING When leaving the operator's compartment, set the work equipment lock lever securely to the LOCK position. If the work equipment lock lever is not at the LOCK position and the control levers are touched by mistake, it may lead to serious personal injury.
Page 86 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE LEVER WARNING When parking the machine, always set the parking brake lever in the LOCK position. If the parking brake lever is operated, the brake is applied, even when the machine is traveling. The machine will suddenly stop, so this is dangerous. For this reason, do not operate the parking brake lever when the machine is moving, except in emergencies.
Page 87 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Gear shifting When the steering, directional, and gearshift lever is at the FORWARD or REVERSE position and switch (c) or switch (d) is pushed, the transmission speed will change. UP switch (c): Each time the switch is pressed, the transmission will shift up one speed.
Page 88 OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING Do not place your foot on this pedal unnecessarily. Depress the pedal (4) 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 89 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER FOR POWER TILT DOZER This lever (6) is used to lift or tilt the blade. 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. REMARK If the lever is in the FLOAT position, even when it is released, it does not return to the HOLD position, so return it by hand.
Page 90 OPERATION EXPLANATION OF COMPONENTS SINGLE TILT DOZER This lever (6) is used to lift the blade. 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. REMARK If the lever is in the FLOAT position, even when it is released, it does not return to the HOLD position, so return it by hand.
Page 91 OPERATION EXPLANATION OF COMPONENTS VARIABLE MULTI-SHANK RIPPER SPECIFICATION Lift operation (a) RAISE (b) HOLD: Ripper is stopped and held in the same position. (c) LOWER Tilt operation (A) Tilt in (B) Tilt back 3 - 44...
Page 92: Fuse
OPERATION EXPLANATION OF COMPONENTS FUSE NOTICE Before replacing a fuse, be sure to turn starting switch to the OFF position. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse. Replace the fuse with another of the same capacity.
Page 93 OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND CIRCUIT NAME Fuse box (A) Fuse Circuit capacity Additional heater, Spere power source Horn, Intake air heater Head lamp Rear lamp Transmission Steering controller Fuse box (B) Fuse Circuit capacity Monitor panel Fuel pump Air conditioner Backup alarm Battery power source (direct from battery)
Page 94: Main Power Circuit Breakers
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 95: Power Source
OPERATION EXPLANATION OF COMPONENTS POWER SOURCE NOTICE The power for the cigarette lighter is 24V. Do not use it as the power source for 12V equipment. The cigarette lighter socket (1) can be used as a power source for 24V equipment and the accessory socket (2) can be used for 12V equipment.
Page 96: Cap With Lock
OPERATION EXPLANATION OF COMPONENTS CAP WITH LOCK Lock-type caps are available for the radiator water filler cap, hydraulic tank oil filler cap, and fuel tank filler cap. For details of the locations of the caps with locks, see "LOCKING (PAGE 3-126)". Use the starting switch key to open and close the locks on the caps.
Page 97 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPENING HYDRAULIC CAP OPENING THE CAP 1. Insert the key. Make sure that you have inserted the key fully (1) before turning it. If the key is turned when only partially inserted, it may break. 2.
Page 98: Door Open Lock
OPERATION EXPLANATION OF COMPONENTS DOOR OPEN LOCK Use this when your want to keep the door held open. 1. Push the door against door catch (1). The door will be held by the door catch. 2. To release the door, move lever (2) inside the cab forward. This will release the catch.
Page 99: Door Pocket
OPERATION EXPLANATION OF COMPONENTS DOOR POCKET This is inside the left and right doors. Use it for storing the Operation and Maintenance Manual or other things. Do not put heavy tools or other heavy objects in it. If the pocket is dirty, turn 4 clips (1), then remove the pocket and rinse it.
Page 100: Air Conditioner
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER (Machine equipped with cab) GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL Fan switch Fresh/recirc selector switch Air conditioner switch Temperature control switch FAN SWITCH This switch (1) can be used to adjust the airflow in four stages. It also acts as the main switch for the air conditioner.
Page 101 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidifying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
Page 102 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH This switch (4) can be used to adjust the temperature steplessly between low temperature and high temperature. The temperature level indicator lamps (A) light up to display the temperature of the air coming from the vents. The more blue lamps on, the lower the temperature is.
Page 103 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS When defrosting, set the temperature control switch so that all lamps are red. This will improve defrosting and demisting. 3 - 56...
Page 104 OPERATION EXPLANATION OF COMPONENTS WHEN NOT USING THE AIR CONDITIONER REGULARLY Run the air conditioner in cooling or dehumidification + heating mode for several minutes from time to time to prevent the loss of the oil film in various parts of the compressor. REMARK If the temperature inside the cab is low, the air conditioner may not work.
Page 105 OPERATION EXPLANATION OF COMPONENTS CHECKS DURING OFF-SEASON Even during the off-season, run the compressor at low speed for several minutes once a week to prevent the loss of the oil film on the lubricated parts of the compressor. (Run the engine at low speed and set to a mid-range temperature when carrying out this operation.) REMARK When the ambient temperature is low, if the compressor is suddenly run at high speed, it may cause failure of the compressor.
Page 106: Heater, Handling
OPERATION EXPLANATION OF COMPONENTS HEATER, HANDLING (Machine equipped with cab) (If equipped) METHOD OF OPERATION Switch Humidity RECIRC/FRESH Fan switch control switch selector switch Condition of use Rapid heating All red RECIRC Ventilation or HI - LO All blue FRESH pressurization TO HEAT QUICKLY If the switch is operated as follows, the cab can be heated quickly.
Page 107: Car Stereo, Handling
OPERATION EXPLANATION OF COMPONENTS CAR STEREO, HANDLING (Machine equipped with cab) (If equipped) 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...
Page 108 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.
Page 109 OPERATION EXPLANATION OF COMPONENTS TREBLE CONTROL KNOB Turn this button (4) to the left to reduce the low tones; turn it to the right to emphasize the high tones. Direction (a): High tone reduced Direction (b): High tone emphasized LOUDNESS BUTTON This button (5) is used when playing at low volume.
Page 110 OPERATION EXPLANATION OF COMPONENTS TAPE EJECT BUTTON This button (7) is used to stop the tape and to eject the cassette. When this button is pressed, the tape is ejected and the radio plays. CASSETTE DOOR Set the cassette with the exposed portion of the tape on the right side and insert it through the cassette door (8).
Page 111 OPERATION EXPLANATION OF COMPONENTS METAL TAPE BUTTON (used also for preset button No. 5) This button (11) is used when playing a metal or chrome tape. This button is also used for preset button No. 5. When it is pressed, "MTL"...
Page 112 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS It is possible to preset 6 MW (AM) stations and 12 FM stations (FM1: 6 stations, FM2: 6 stations). REMARK If you are playing the cassette, press the tape eject button to stop the tape. METHOD OF AUTO PRESET 1.
Page 113 OPERATION EXPLANATION OF COMPONENTS LISTENING TO RADIO 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Use band selector button (2) to select MW (AM), FM1 or FM2. 3. Select the station with the preset buttons (3). REMARK In case you do not promptly remember the number assigned to a certain preset station, press auto-store/preset scan button (4) for...
Page 114 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 115: External Power Source Type Engine Preheating Heater
OPERATION EXPLANATION OF COMPONENTS EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER For cold weather (ambient temperature -30°C (-22°F)) This preheater is used as a starting aid when it is difficult to start the engine because of the cold temperature. It is used even when the ambient temperature is above -20°C (-4°F) in seasons where the temperature goes down to -20°C (-4°F).
Page 116 OPERATION EXPLANATION OF COMPONENTS 4. Manufacturing external power source input cable The external power source input cable must be manufactured locally to match the local conditions. This does not mean that any cable can be used. Manufacture the cable as follows. 1) For the wiring, purchase three-core chloroprene sheath cab tire cable locally.
Page 117 OPERATION EXPLANATION OF COMPONENTS 3) Modify the other end of the cable so that it can be connected to the power supply equipment. When the modification of the connection is finished, the external power source input cable is completed. 5. Establishing power supply WARNING When setting up the power supply equipment, follow all the related laws and regulations in that country and use an authorized contractor.
Page 118 OPERATION EXPLANATION OF COMPONENTS Specifications for power supply equipment Type of output electricity: Single-phase alternating current Output voltage: 200 - 240 volts (V) Supply capacity: 8.5 kilovolt amperes (kVA) Main switch: Yes Electric leakage breaker: Yes Ground circuit: Yes System diagram, overall wiring diagram (for reference when carrying out the work) System diagram for external power supply type engine preheater 3 - 71...
Page 119 OPERATION EXPLANATION OF COMPONENTS Overall wiring diagram for external power supply type engine preheater 3 - 72...
Page 120 OPERATION EXPLANATION OF COMPONENTS HANDLING PROCEDURE Use this engine preheating heater in a season when the ambient temperature goes down below - 20°C (4°F), or when it is difficult to start the cold engine though the ambient temperature stays above - 20°C (4°F). NOTICE For details of the oil to use, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-10)".
Page 121 OPERATION EXPLANATION OF COMPONENTS 2. Turn the power for the engine preheating heater on several hours before starting the engine to warm up the coolant and oil in the engine oil pan. 1) Connect the power supply to the input socket on the machine with a cable.
Page 122 OPERATION EXPLANATION OF COMPONENTS 3. The time to keep the electricity on differs according to the ambient temperature and the type of oil being used. Min. ON time for Ambient temperature Type of oil electricity -30 ° C (-22 ° F) SAE 10W Min.
Page 123: Before Starting Engine
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 124 OPERATION OPERATION 8. Check for damage to seat belt and mounting clamps Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with new parts. 3 - 77...
Page 125 OPERATION OPERATION CHECK BEFORE STARTING Always check the items in this section before starting the engine each day. 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.
Page 126 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 127 OPERATION OPERATION CHECK DUST INDICATOR This is on the air cleaner bracket inside the engine room. This device indicates that the air cleaner element is clogged. For details on how to clean the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-24)". 1.
Page 128 OPERATION OPERATION CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT 1. Open the side cover on the left side of the machine. The water separator and pre-fuel filter form one unit and are at the bottom. 2. It is possible to judge the water level and amount of sediment by looking through transparent cap (2).
Page 129 OPERATION OPERATION CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. 1.
Page 130 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 push the cap down to release the internal pressure before removing the cap carefully.
Page 131 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 MACHINE MONITOR 1. Turn starting switch (1) to the ON position.
Page 132 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If the fuel is spilt, wipe it off completely. 1. Turn the starting switch to the ON position and check the fuel level with fuel gauge (G) on the monitor panel.
Page 133 79 mm (2.7 to 3.1 in). 3. When this value exceeds 80 mm (3.2 in), or the brake fails to work, please contact your Komatsu distributor for adjustment. CHECK THAT LAMPS LIGHT UP 1. Turn starting switch key to the ON position.
Page 134 Check that the horn sounds. If it does not sound at all or the sound is extremely feeble, a defect or broken wire is suspected, ask your Komatsu distributor for possible repairs. 1. Turn starting switch key to the ON position.
Page 135 OPERATION OPERATION CHECK BACKUP ALARM SOUND Check that the backup alarm sounds normally. If it does not, a defect or broken wire is suspected, ask your Komatsu distributor for possible repairs. 1. Turn the starting switch to the ON position.
Page 136 OPERATION OPERATION ADJUSTMENT ADJUSTING OPERATOR'S SEAT WARNING When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to prevent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 137 OPERATION OPERATION OPERATION OPERATION (D) Adjusting direction of seat Pull up lever (5) to unlock the seat. The seat can then be turned 15 ° to the right. After changing the direction of the seat, return the lever securely to lock the seat.
Page 138 OPERATION OPERATION ADJUST MIRROR Loosen nut (1) of the mirror and adjust the mirror to a position where it gives the best view from the operator's seat. In particular, be sure to adjust the mirror so that people at the rear left or right of the machine can be seen clearly.
Page 139 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 140 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 141 OPERATION OPERATION OPERATION OPERATION 3. Check that the blade is lowered to the ground and that blade control lever (3) is in the HOLD position. 4. Check that the ripper is lowered to the ground. 5. Check that work equipment lock lever (4) is locked. If work equipment lock lever (4) is locked, the blade control lever is returned to the HOLD position even if it is in the FLOAT position.
Page 142: 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 143 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. 3 - 96...
Page 144 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 145 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 engine pre-heating pilot lamp (3) goes off, turn the key of starting switch (2) to the START position to crank the engine.
Page 146 OPERATION OPERATION 7. When the engine rotation stabilizes, return to the low idle (MIN) position of fuel control dial (1) and then carry out the warming-up operation. REMARK Regardless of the ambient temperature, if the key in starting switch (2) is turned from OFF position to left, preheating pilot lamp (3) will light up and preheating will start.
Page 147: Operations And Checks After Starting Engine
OPERATION OPERATION OPERATIONS AND CHECKS AFTER STARTING ENGINE WARNING If there has been any Emergency stop, abnormal actuation or trouble, turn the starting switch key to the OFF position. If the work equipment is operated without sufficiently warming the machine up, response of the work equipment to movement of the control lever will be slow, and the work equipment may not respond as the operator desires, so always perform the warming-up operation.
Page 148 (2) is within the green range (B). (A): White range (B): Green range (C): Red range 3. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 101...
Page 149 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 - 102...
Page 150: 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 151: Machine Operation
OPERATION OPERATION MACHINE 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 152 (6) and allow the machine to move. REMARK Check that the backup alarm sounds when steering, forward-reverse, gear shift lever is placed in REVERSE position. If the alarm does not sound, please contact your Komatsu distributor. 3 - 105...
Page 153 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 154: 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 Press switch (a) or (b) to shift gears. Up switch (a): Each time switch is pressed, transmission shifts up 1 range Down switch (b): Each time switch is pressed, transmission shifts...
Page 155 OPERATION OPERATION GEARSHIFTING OPERATION USING PRESET MODE FUNCTION If the preset mode function is used, the speed ranges used when the machine travels in forward and reverse can be preset as desired. F1-R1 mode F1-R2 mode F2-R2 mode 1. Set joystick (1) to the N position. 2.
Page 156 OPERATION OPERATION 4. If it is desired to select another mode, press up switch (a) or down switch (b) on steering, directional, and speed lever (1) and display the desired mode on control panel B (multi-information). The types of mode and method of selection are as follows. →...
Page 157 OPERATION OPERATION AUTO SHIFT DOWN FUNCTION If the travel speed drops because of the load conditions when traveling, this function automatically down shifts to a lower speed range. 1. The function is actuated when auto shift down switch (4) on the front panel is set to position (ON).
Page 158: 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 159 REVERSE position. If the alarm does not sound, please contact your Komatsu distributor. REMARK When the joystick is placed in REVERSE, the backup alarm will sound. 3 - 112...
Page 160: 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 WARNING When performing a counterrotation turn, the feeling of operation when your head is facing the rear is different from the feeling if...
Page 161 OPERATION OPERATION COUNTERROTATION TURNS TO LEFT WHEN TRAVELING FORWARD NOTICE When carrying out a counterrotation turn, if the load is not equal on the left and right sides, the machine may carry out a pivot turn, so check the ground conditions and be careful not to hit any obstacles. With steering, forward-reverse, gear shift lever (1) in the N position, operate the lever partially to the left (L).
Page 162 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 163 OPERATION OPERATION PRECAUTIONS WHEN OPERATING BLADE METHOD OF USING BLADE LIFT CYLINDER Do not carry out back grading operations with the cylinder fully extended. There is high risk that an excessive load will be brought to bear on the cylinder. 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...
Page 164 OPERATION OPERATION METHOD OF USING BRAKES The following actions cause premature damage to the brakes, so avoid such operations. Using emergency brake at full speed Using brake with engine running at full speed in first gear (F1, R1) (Machine stall condition) REMARK Always depress the decelerator pedal to lower the engine speed before actuating the brakes.
Page 165: Work Possible Using Bulldozer
OPERATION OPERATION WORK POSSIBLE USING BULLDOZER In addition to the following, it is possible to further increase the range of applications by using various attachments. 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 166 OPERATION OPERATION PUSHER OPERATIONS When carrying out pusher operations, always install a pusher plate. When approaching the other machine, depress the decelerator pedal to reduce the engine speed and approach slowly. After coming into contact, raise the travel speed slowly and push with full power.
Page 167: 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 168 OPERATION OPERATION ADJUSTING DIGGING ANGLE (PX Specifications) It is possible to change the digging angle (A) of the blade by removing cap (1) and bolt (2) installed between the blade and tilt cylinder or brace (3), or replacing with optional parts. This is extremely effective in improving the earth rolling function of the blade on soft ground without using the tilt cylinder to change the left and right tilt.
Page 169 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. Start the engine, then use fine operation of the blade control lever to tilt to the left and right.
Page 170 OPERATION OPERATION ADJUSTING RIPPER ADJUSTING DIGGING DEPTH Mounting pin holes are provided in the shank and these are used according to the desired digging depth. For normal use, use the bottom hole, and when particularly deep digging is needed, use the top hole. 1.
Page 171: 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 172 OPERATION OPERATION OPERATION OPERATION 3. Set parking brake lever (4) to the LOCK position. 4. Operate blade control lever (5) and ripper control lever (6) to the LOWER position, and lower the blade and ripper to the ground. 5. Set blade control lever (5) and ripper control lever (6) to the HOLD position.
Page 173: Check After Finishing Work
OPERATION OPERATION CHECK AFTER FINISHING WORK BEFORE STOPPING ENGINE Use the meters and caution lamps to check the engine coolant temperature, engine oil pressure, fuel, and power train oil temperature. 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.
Page 174: 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 175 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 176 OPERATION OPERATION MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 1. Measure height (size C) of link tread as shown. 2. Stop machine at position where link tread, whose size C has been measured completely, contacts roller tread. Then measure size B. 3.
Page 177 OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION PROCEDURE As a rule, transport the machine on a trailer. Select a trailer according to the mass and dimensions of the machine shown in "SPECIFICATIONS (PAGE 5-2)". Note that the mass and dimensions for transportation shown in SPECIFICATIONS depend on the types of shoe, blade, etc.
Page 178: Installation Of Cab
Tighten in the order (N), (U), (Q), (R), (O), (T), (P), (S). 4. Tighten the bolts, (A) to (M), completely. If there are any unclear points about removing or installing the cab, please contact your Komatsu distributor. INSTALLATION OF ROPS NOTICE ROPS is an important component for ensuring safety.
Page 179: Loading, Unloading Work
OPERATION TRANSPORTATION LOADING, UNLOADING WORK WARNING Since loading and unloading of the machine is dangerous, be extremely careful. When loading or unloading the machine, operate it slowly with the engine speed low and the transmission in the 1st gear. Use ramps having sufficient width, length, thickness, and strength. Install them securely and set their angle to 15° or less. If the ramps are deflected appreciably, reinforce them with blocks.
Page 180 OPERATION TRANSPORTATION SECURING MACHINE NOTICE Be sure to lower the car radio antenna to the stow position (if the machine is equipped with a cab). Load the machine onto a trailer as follows: 1. Lower the work equipment slowly. (When transporting with work equipment installed) 2.
Page 181 OPERATION OPERATION TRANSPORTATION TRANSPORTATION 4) Secure the attachment at two places with a chain or wire rope. UNLOADING 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move.
Page 182: Method Of Lifting Machine
This method of lifting applies to the standard specification 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. For weight, see "SPECIFICATIONS (PAGE 5-2)".
Page 183: Precautions For Transportation
OPERATION OPERATION TRANSPORTATION TRANSPORTATION 3. Install wire ropes, slings, etc. matched to the weight of the machine to the lifting points as shown in the diagram on the right. 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.
Page 184: 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 185 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 186: After Completion Of Work
OPERATION COLD WEATHER OPERATION AFTER COMPLETION OF WORK 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. Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean to prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
Page 187: Long-Term Storage
Place all control levers in the neutral position, set the work equipment lock lever and parking brake lever in 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 188: 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 189: Method Of Towing Machine
To move the machine in this case, the oil pressure in the brake circuit must be heightened to the specified level with a special device. Ask your Komatsu distributor. Moving a machine by towing is only used to move it to a place where it is possible to carry out inspection and maintenance.
Page 190 OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING If the machine sinks in mud and cannot get out under its own power, or if being used to tow a heavy object, fit the wire to the towing hook as shown in the diagram on the right, or in the case of machines with a drawbar, fit the wire to the drawbar pin when towing.
Page 191: 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 192 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 3-144)" and the instructions given in the charger manual, and always do as follows. Set the voltage of the charger to match the voltage of the battery to be charged.
Page 193 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 194 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 195: 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 cause Remedy Lamp does not glow brightly even...
Page 196 Note: If a problem display appears on display panel B, check the fault code. For details, see "METHOD OF USING FAULT CODE DISPLAY MODE (PAGE 3-30)". When contacting your Komatsu distributor, please give the fault code also. 3 - 149...
Page 197 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 Improper tightening of oil pipe,...
Page 198 OPERATION TROUBLESHOOTING Problem Main causes Remedy Lack of hydraulic oil Add oil to specified level. For details, see EVERY 250 HOURS blade rises too slowly or dose not SERVICE rise at all Defective hydraulic pump Check (or blade tilts too slowly) Work equipment lock lever is at Set to FREE position LOCK position...
Page 199 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 Engine oil pan oil level is low...
Page 200 4 - 1...
Page 201: Guides To 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 202 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: Inspect the dust indicator more frequently to see if the air cleaner is clogged. Clean the air cleaner element at a shorter interval than specified. On machines equipped with an air cleaner clogging monitor, the check can be carried out with the monitor. Clean the radiator core frequently to avoid clogging.
Page 203 MAINTENANCE GUIDES TO MAINTENANCE CHECKS AFTER INSPECTION AND MAINTENANCE: If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do the following: Checks after operation (with engine stopped) Have any inspection and maintenance points been forgotten? Have all inspection and maintenance items been performed correctly? Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped...
Page 204: Outlines Of Service
Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil. FUEL To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day's work.
Page 205 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 206: Index
Perform sampling at regular fixed intervals. Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. STORING OIL AND FUEL Keep indoors to prevent any water, dirt, or other impurities from getting in.
Page 207: 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 208: Wear Parts
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 209: 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 210: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ASTM: American Society of Testing and Material 4 - 11...
Page 211: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications, refer to the Komatsu web page or consult your Komatsu distributor. 4 - 12...
Page 212: 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 213: 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 214 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q'ty Replacement frequency 20 Hose between PCC divider block - fan pump 21 Hose between PCC divider block - main control lock valve 22 Hose between oil cooler bypass valve - hydraulic oil cooler 23 Hose between self-reducing pressure valve - central drain block 24 Hose between main control valve - central drain block 25 Hose between fan motor - hydraulic tank...
Page 215: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART The maintenance interval for adjusting the injector differs according to the exhaust gas regulations for each area. When carrying out the adjustment, check the maintenance time. For details, see "ADJUST INJECTOR (PAGE 4-18)".
Page 216 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 500 HOURS SERVICE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 52 REPLACE PRE-FUEL FILTER CARTRIDGE 4- 53 REPLACE POWER TRAIN OIL FILTER ELEMENT 4- 55 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL 4- 55 EVERY 1000 HOURS SERVICE CHANGE OIL IN POWER TRAIN CASE, WASH STRAINER (POWER TRAIN PUMP STRAINER,...
Page 217: Adjust Injector
When transporting a machine from an A regulation area to a B regulation area, always replace all the injector assemblies before transporting the machine to the new area. Check with your Komatsu distributor to confirm if your area of operation is an A regulation area or a B regulation area. A REGULATION AREA...
Page 218: 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 power train case oil and wash strainer (power train pump strainer, scavenging pump strainer) Change oil in final drive case Change oil in hydraulic tank, replace hydraulic oil filter element, clean hydraulic tank strainer For details of the methods of maintenance, see EVERY 500 HOURS SERVICE, EVERY 1000 SERVICE, EVERY...
Page 219: 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 220 MAINTENANCE SERVICE PROCEDURE When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table given below. It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio. The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/total amount of coolant x 100).
Page 221 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 1. Stop the engine, wait for the coolant to cool completely, then turn valve (2) of corrosion resistor (1) to the Close stopper position. 2. Turn main radiator cap (3) slowly, and remove. 3. Prepare a container to catch the coolant, pull out hose (4) of the main radiator at the bottom front right of the machine, then open drain valve (5) and drain the water.
Page 222 MAINTENANCE SERVICE PROCEDURE 9. Replace the corrosion resistor, then open each valve (3). For details of the procedure for replacing the corrosion resistor, see "REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-62)". 10. Close drain valve (5), (6). 11. Add coolant mixed with antifreeze until it overflows from the water filler. Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze.
Page 223 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 224 MAINTENANCE SERVICE PROCEDURE CLEANING OR REPLACING OUTER ELEMENT NOTICE Before and after cleaning the element, do not leave or keep it in direct sunlight. 1. Open the left engine side cover. 2. Remove three clips (2), then remove cover (3). NOTICE Never remove inner element (5).
Page 225 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE When cleaning the element, do not hit or beat it against anything. Do not use an element whose folds or gasket or seal are damaged.
Page 226 MAINTENANCE SERVICE PROCEDURE REPLACING ELEMENT 1. Open the left engine side cover. 2. Remove three clips (2), then remove cover (3). 3. Remove outer element (4). Do not remove inner element (5) at this time, however. 4. Clean the interior of the air cleaner body, cover (3) and evacuator valve (6).
Page 227 (1). Furthermore, do not get any part of your body in front of the grease fitting. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. WHEN INCREASING TENSION 1. Pump in grease through grease fitting with a grease pump.
Page 228 It is extremely dangerous to release the grease by any method except the procedure given below. If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs. 1. Loosen lubricator (1) gradually to release the grease.
Page 229 MAINTENANCE SERVICE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. METHOD OF TIGHTENING SHOE BOLT 1. First, tighten to the tightening torque below, then check that the nut and shoe are in close contact with the link mating surface.
Page 230 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 231 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 232 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 233 MAINTENANCE SERVICE PROCEDURE CLEAN, CHECK RADIATOR FINS AND OIL COOLER FINS Carry out this procedure if there is any mud or dirt stuck to the radiator or oil cooler. REMARK Check the hydraulic cooler hoses. If any hose is cracked or hardened by age, replace with a new hose. Also check and tighten all loose hose clamps.
Page 234 MAINTENANCE SERVICE PROCEDURE 8. Turn starting switch (1) to the "ON" position. 9. Turn the fan rotation selector switch (2) to the normal rotation position (a) and cancel the reverse rotation. REMARK If dirt is caught in the radiator fins, blow with compressed air to clean. CLEANING WITH COMPRESSED AIR WARNING Directing compressed air, pressurized water, or steam directly at your body, or using these and causing dust to fly may cause...
Page 235 MAINTENANCE SERVICE PROCEDURE CLEAN FUEL TANK STRAINER Clean the strainer if there is any dirt collected in it. Remove the filler cap (1) of the fuel tank and take out strainer. If the strainer is dirty, clean it with diesel fuel. DRAIN WATER AND SEDIMENT IN FUEL TANK Carry out this procedure after the machine has been at rest for a long time and after a long spell of rainy days.
Page 236 If oil oozes out, the oil level has not gone down, so tighten the bolt. 2. If no oil comes out even when seal bolt is removed, the oil level is low. Contact your Komatsu distributor for repairs. 4 - 37...
Page 237 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. In places where there is a lot of dust, clean the air filter once a week. In addition, clean the air conditioner air filter at the same time, when cleaning the engine air cleaner.
Page 238 MAINTENANCE SERVICE PROCEDURE REPLACE 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 239 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 If the control lever is touched by accident during checking, the machine moves off suddenly, and this may lead to serious injury or death.
Page 240 MAINTENANCE SERVICE PROCEDURE REPLACE DOOR DAMPER If the depth of the door damper rubber groove is less than 2 mm (0.08 in), replace the damper. There are four dampers each at the top and bottom on the left and right doors. CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level and add fluid.
Page 241 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 242 MAINTENANCE SERVICE PROCEDURE BLEEDING AIR IN HYDRAULIC SYSTEM See "OPERATIONS AND CHECKS AFTER STARTING ENGINE (PAGE 3-100)". 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 243: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-78)". Check oil level in engine oil pan, add oil Check coolant level, add coolant Check dust indicator Check water separator, drain water and sediment Check oil level in power train case, add oil Check oil level in hydraulic tank, add oil Check electric wiring...
Page 244: 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. (1) Blade lift cylinder support yoke (4 places) REMARK These are at the front and rear of the left and right cylinders.
Page 245 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE (9) Ripper arm pin (front) (2 places) (10) Ripper arm pin (rear) (2 places) (11) Lift cylinder bottom pin (2 places) (12) Lift cylinder head pin (2 places) (13) Tilt cylinder bottom pin (2 places) (14) Tilt cylinder head pin (2 places) (9) - (14) indicate the greasing points for the variable multi-shank ripper specification.
Page 246 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 247 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 - 48...
Page 248 If water is added to above the bottom tip of the sleeve, use a pipette to remove electrolyte. 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 249 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 250 MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 1. Open the engine side cover on the left side of the chassis. 2. Remove dipstick (G) and wipe the oil off with a cloth. 3. Fully insert dipstick (G) into filler pipe (F), then remove it. 4.
Page 251: Every 500 Hours Service
2. Loosen drain plug (P) (with a slit) slowly to avoid getting oil on yourself, and drain the oil. 3. Check the drained oil, if there is excessive metal particles or foreign material, contact your Komatsu distributor. 4. Install drain plug (P). 5. Using a filter wrench, turn filter cartridge (1) counterclockwise to remove it.
Page 252 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 253 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 6. Check that the drain plug(4) at the bottom of the pre-fuel filter cup(3) is tightened securely. Tightening torque: 0.2 to 0.45 Nm (0.02 to 0.046 kgm , 0.1 to 0.3 lbft) 7. Clean the filter holder. NOTICE When filling the filter cartridge with fuel, carry out the filling operation with cap (A) fitted.
Page 254 MAINTENANCE SERVICE PROCEDURE REPLACE POWER TRAIN OIL FILTER ELEMENT WARNING Immediately after the engine is stopped, the oil and parts are at high temperature, and may cause burns. To prevent this, wait for the temperature to go down before starting the operation. Before opening the filter cases, depress the brake pedal several times to release the pressure, then lock the brake pedal.
Page 255: 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 256 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3) Lower cover (2) slowly and open it. (The right side of the cover has a hinge.) The strainer can be seen at portion P at the top. 4. Remove drain plug (P2) in the strainer cover, and drain the oil (approx.
Page 257 MAINTENANCE SERVICE PROCEDURE REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, oil may spurt out, so push the cap down to release the internal pressure, then remove the cap carefully.
Page 258 MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN FINAL DRIVE CASE 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. There is danger that oil spouts out due to the internal pressure. When removing the plug, work from the side, turn the plug slowly to release the internal pressure, and remove it carefully.
Page 259 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 260 When only the filter cartridge is replaced, it is suffficient that air bleeding is carried out for the filter head alone. But when the fuel piping is removed, air bleeding should also be carried out for the injection pump air-bleeding valve. CHECK TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. 4 - 61...
Page 261 MAINTENANCE SERVICE PROCEDURE REPLACE CORROSION RESISTOR CARTRIDGE WARNING If the engine has been operated, all parts will be at a high temperature, so never try to replace the cartridge immediately after stopping the engine. Always wait for the engine and other parts to cool down. Container to catch drained coolant Prepare a filter wrench for fuel filter element.
Page 262: 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, CLEAN HYDRAULIC TANK STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 263 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. Remove bolts (5), then remove cover (6) and take out the strainer. 8. Wash the strainer in clean diesel oil or flushing oil. 9. Install the strainer to its original position. 10. Add the refill amount of engine oil through oil filler port (F), then install the cap. When installing cap to the tank, push it down, then turn it clockwise.
Page 264 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 2. Remove the undercover (1) at the bottom rear of the chassis as follows. 1) Remove 2 bolts (2) at the Right of machine. 2) Hold cover (1) in position and gradually remove 2 bolts (3) at the Left of machine.
Page 265 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 266 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3. Raise the work equipment (blade) to the maximum height. NOTICE Carry out the following procedure for lowering the blade to the ground within 15 seconds after stopping the engine. When the engine is stopped, the pressure inside the accumulator gradually goes down, so this inspection can be carried out only immediately after the engine is stopped.
Page 267 MAINTENANCE SERVICE PROCEDURE In the following cases, the charge pressure of the accumulator has gone down. Please contact your Komatsu distributor. Work equipment does not go down Stops while going down METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT NOTICE Finish the steps of operating the blade control lever to the front and back, and to the right and left, to each stroke end within 15 seconds after the engine has stopped.
Page 268 (behind the radiator). 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 269: Every 4000 Hours Service
Please ask your Komatsu distributor to replace the accumulator. CHECK WATER PUMP Check for oil and coolant leakage, or clogging of the drain hole. If any abnormality is found, contact your Komatsu distributor for disassembly, repair, or replacement. CHECK INJECTOR See Section "B REGULATION AREA (PAGE 4-18)".
Page 270 Check visually and touch with your fingers to check that there are no loose bolts or hardening of rubber parts at clamps (1) to (10). If there is any looseness or hardened rubber, contact your Komatsu distributor for replacement. NOTICE If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is danger of damage or breakage occurring due to vibration and wear at the connections of high-pressure piping.
Page 271 If there is any problem, the problem part must be replaced. Contact your Komatsu distributor for part replacement. 4 - 72...
Page 272 Carefully check the base material of the steel casting and welding at portions (A) - (L), and check that there is no damage. If any cracks or other damage is found, repair them. Contact your Komatsu distributor for details of the repair procedure. 4 - 73...
Page 273: Every 8000 Hours Service
See Section "B REGULATION AREA (PAGE 4-18)". 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 - 74...
Page 274 5 - 1...
Page 275 3,345 (7,376) Ripper unit weight(Multi ripper) kg (lb) 2,215 (4,884) Drawbar unit weight kg (lb) 176 (388) Name of engine KOMATSU SA6D125E-3 diesel engine Engine horsepower kW(HP)/rpm 179 (240)/1,900 A Overall length mm (ft in) 7,255 (23'10") 6,065 (19'11") B Overall height mm (ft in) 3,330 (10'11")
Page 276 6 - 1...
Page 277: 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 278: Selection Of Track Shoe
ATTACHMENTS, OPTIONS SELECTION OF TRACK SHOE SELECTION OF TRACK SHOE Select suitable track shoes to match the operating conditions. METHOD OF SELECTING SHOES If a wider shoe than necessary is used, the load on the track will increase, and this will cause the shoes to bend, links to crack, pins to break, shoe bolts to come loose, and various other problems.
Page 279: Procedure For Selecting Ripper Point
ATTACHMENTS, OPTIONS PROCEDURE FOR SELECTING RIPPER POINT PROCEDURE FOR SELECTING RIPPER POINT 6 - 4...
Page 280: Handling Trimming Dozer
ATTACHMENTS, OPTIONS HANDLING TRIMMING DOZER HANDLING TRIMMING DOZER GENERAL VIEW GENERAL VIEW OF MACHINE Blade Trimming cylinder Lift cylinder Cutting edge Frame 6 - 5...
Page 281 ATTACHMENTS, OPTIONS HANDLING TRIMMING DOZER 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. CONTROL LEVERS AND PEDALS WORK EQUIPMENT LOCK LEVER WARNING...
Page 282: Maintenance
ATTACHMENTS, OPTIONS HANDLING TRIMMING DOZER MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART EVERY 250 HOURS SERVICE LUBRICATING CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL EVERY 2000 HOURS SERVICE CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT AND CLEAN HYDRAULIC TANK STRAINER 6 - 7...
Page 283 ATTACHMENTS, OPTIONS HANDLING TRIMMING DOZER 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. (1) Frame shaft (2 places) (2) Support shaft (2 places) (hydraulic cylinder for trimming)
Page 284 ATTACHMENTS, OPTIONS HANDLING TRIMMING DOZER EVERY 2000 HOURS SERVICE Carry out the maintenance for EVERY 250 HOURS SERVICE at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT AND CLEAN HYDRAULIC TANK STRAINER 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 285 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING TRIMMING DOZER HANDLING TRIMMING DOZER 7. Remove bolts (5), then remove cover (6) and take out the strainer. 8. Wash the strainer in clean diesel oil or flushing oil. 9. Install the strainer to its original position. 10.
Page 286 ATTACHMENTS, OPTIONS HANDLING TRIMMING DOZER SPECIFICATIONS D85EX-15 Item Unit Trimming dozer Weight of bare machine (*1) kg (lb) 3,810 (8,401) Operating weight (*2) kg (lb) 25,760 (56,801) Hydraulic equipment Pump type Force-feed plunger pump type Hydraulic oil Engine oil CD SAE10W l (US gal) Hydraulic oil amount 106 (28.01)
Page 287: 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 288 INDEX INDEX <A> GAUGES ADJUSTING POSTURE OF WORK GENERAL VIEW OF MACHINE EQUIPMENT 3-120 GUIDES TO MAINTENANCE AIR CONDITIONER 3- 53 ASHTRAY 3- 52 <H> HANDLING MACHINES EQUIPPED <B> WITH KOMTRAX 6- 12 BREAKING IN THE MACHINE BASIC PRECAUTIONS 6- 12 HANDLING OIL, FUEL, COOLANT, AND <C>...
Page 289 INDEX <P> WHEN REQUIRED 4- 20 PARKING MACHINE 3-124 SHIFTING BETWEEN FORWARD AND PERIODIC REPLACEMENT OF SAFETY REVERSE 3-111 CRITICAL PARTS 4- 14 SHIFTING GEAR 3-107 POSITION OF SERVICE METER SPECIFICATIONS POWER SOURCE 3- 48 STANDARD TIGHTENING TORQUES PRECAUTIONS FOR MAINTENANCE 2- 27 FOR BOLTS AND NUTS 4- 13...

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