Page 1 Operation & EEAM023900 Maintenance Manual D31EX, PX-21 D37EX, PX-21 D39EX, PX-21 BULLDOZER SERIAL NUMBER D31EX-21 - 50501 and up D31PX-21 - 50501 and up D37EX-21 - 5501 and up D37PX-21 - 5501 and up D39EX-21 -1501 and up D39PX-21 -1501 and up...
Page 3 FOREWORD...
Page 4 Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically. In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
Page 5: Foreword
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 situa- tions.
Page 6 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 7: Noise
FOREWORD SAFETY INFORMATION NOISE q Sound pressure level at the operator's station, measured according to ISO6396 (Dynamic test method, simulated working cycle) q Sound power level emitted. This is the guaranteed value as specified in European directive 2000/14/EC. VIBRATION When used for its intended purpose, levels of vibration for the earthworking machine transmitted from the operator’s seat are lower or equal to the test vibrations for the relative machinery class in compliance with ISO 7096.
Page 8: Introduction
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: q Dozing q Smoothing q Cutting into hard or frozen ground or ditching See the section “WORK POSSIBLE USING BULLDOZER (3-95)“ for further details.
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 This is at the front bottom right of the operator's seat. The design of the nameplate differs according to the territory.
Page 10: Position Of Service Meter
The service meter is provided at the lower part of the monitor panel. TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN Machine serial No. Engine serial No. Product Identification Number Manufacturers name: KOMATSU LTD. Address: 3-6 Akasaka Minato-ku, 101 Tokyo Japan Distributor Address...
Page 11: Machine Serial Plate
FOREWORD NECESSARY INFORMATION MACHINE SERIAL PLATE. Model Seriel Number Manufacturing year Weight Engine power Product Identification Number Manufacturer...
Page 12: Table Of Contents
CONTENTS CONTENTS FOREWORD FOREWORD ................................. 1-2 SAFETY INFORMATION............................1-3 NOISE................................. 1-5 VIBRATION..............................1-5 INTRODUCTION..............................1-6 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE ............... 1-6 NECESSARY INFORMATION ..........................1-7 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........1-7 ENGINE SERIAL NO. PLATE........................1-7 POSITION OF SERVICE METER ......................1-8 TABLE OF ENTER SERIAL NO.
Page 13 CONTENTS OPERATION GENERAL VIEW ..............................3-2 GENERAL VIEW OF MACHINE ......................... 3-2 GENERAL VIEW OF CONTROLS AND GAUGES..................3-3 EXPLANATION OF COMPONENTS........................3-5 FRONT PANEL............................3-5 CHECK MONITOR SYSTEM ......................3-6 EMERGENCY CAUTION ITEMS ...................... 3-7 CAUTION CAUTION ITEMS ......................3-9 METER GROUP ..........................
Page 14 CONTENTS ADJUSTMENT..........................3-72 OPERATION AND CHECK BEFORE STARTING ENGINE............3-75 STARTING ENGINE ..........................3-77 NORMAL STARTING ........................3-77 STARTING IN COLD WEATHER ....................3-79 OPERATIONS AND CHECKS AFTER STARTING ENGINE ..............3-81 BREAKING IN THE NEW MACHINE ....................3-81 WARMING UP OPERATIONS ......................3-81 STARTING IN COLD WEATHER ....................
Page 15 CONTENTS TRANSPORTATION............................3-103 TRANSPORTATION MEANS ......................... 3-103 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT..............3-103 REMOVING CAB ............................ 3-103 LOADING, UNLOADING WORK ......................3-104 LIFTING MACHINE..........................3-108 COLD WEATHER OPERATION ........................3-109 PRECAUTIONS FOR LOW TEMPERATURE ..................3-109 AFTER COMPLETION OF WORK ......................3-111 AFTER COLD WEATHER ........................
Page 16 OIL ..............................4-5 FUEL..............................4-5 COOLANT ............................4-6 GREASE ............................4-6 CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ..............4-6 STORING OIL AND FUEL ......................... 4-7 FILTERS ............................4-7 RELATING TO ELECTRIC SYSTEM ......................4-8 WEAR PARTS LIST ............................. 4-9 WEAR PARTS LIST............................
Page 17 CONTENTS CHECK DOOR LOCK STRIKER ..................... 4-31 CHECK, ADJUST AIR CONDITIONER ................... 4-31 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID .............. 4-33 REPLACE WIPER BLADE ......................4-33 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM............. 4-34 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM ....4-35 CHECK BEFORE STARTING ........................
Page 18 CONTENTS ATTACHMENTS, OPTIONS GENERAL PRECAUTIONS ..........................6-2 PRECAUTIONS RELATED TO SAFETY ....................6-2 HANDLING HYDRAULIC RIPPER........................6-3 GENERAL VIEW............................6-3 EXPLANATION OF COMPONENTS ......................6-4 OPERATION ............................... 6-5 CHECK BEFORE STARTING ENGINE, ADJUST................6-5 PRECAUTIONS WHEN OPERATING....................6-5 ADUSTING POSTURE OF WORK EQUIPMENT ................6-5 TROUBLESHOOTING ..........................
Page 19: Safety
SAFETY WARNING Please be sure that you fully understand this manual and the precautions discribed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precaustions strictly.
Page 20 SAFETY SAFETY SAFETY SAFETY LABELS..............................2-42 POSITION OF SAFETY PICTOGRAMS...................... 2-42 SAFETY LABELS............................2-52 GENERAL PRECAUTIONS Safety rules ..............................2-102 If abnormalities are found........................... 2-102 Clothing and personal protective items ...................... 2-102 Fire extinguisher and first aid kit ........................ 2-102 Safety features ............................
Page 21 SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE ......................2-282 Warning tag..............................2-282 Keep work place clean and tidy ......................... 2-282 Appoint leader when working with others ....................2-282 Stop engine before carrying out inspection and maintenance ..............2-282 Two workers for maintenance when engine is running................2-292 Proper tools..............................
Page 22: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
Page 23: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating machine (09651-A0481) q Warning! q Read manual before operation, maintaince, disassembly, assembly and transportation. (2) Caution before moving in reverse (09802-13000) WARNING To prevents SEVERE INJURY or DEATH, do the following before moving machine or its attachments: q Honk horn to alert people nearby.
Page 24 SAFETY SAFETY LABELS (4) Caution with high-temperature coolant, hydraulic oil (09653-A0481) q Never remove the cap when the engine is at operating (high) temperature. Stream or high temperature oil blowing up from the radiator or hydraulic tank, will cause personal injury and or burns.
Page 25 SAFETY SAFETY LABELS (8) Caution for battery (This plate is stick on the machine by the battery maker) DANGER/POISON EXPLOSIVE GASES Cigarettes, flames or sparks could cause battery to explode. Always shield eyes and face from battery. Do not charge or use booster cables or adjust post connections without order instruction and training.
Page 26 If some modification is applied to the ROPS or FOPS, it might not enough strength and might not be complied with the standard. Consult Komatsu distributor before altering. q ROPS or FOBS may provide less protection if it has been structurally damaged or involved roll-over.
Page 27 SAFETY SAFETY LABELS (13) Caution with high-temperature parts (09817-A0753) q Sign indicates a burn hazard from touching heated parts, such as engine, motor, or muffler during or right after oper- ation. q Never toch when hot.
Page 28: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES q Only trained and authorized personnel can operate and maintain the machine. q Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
Page 29: Safety Features
SAFETY GENERAL PRECAUTIONS SAFETY FEATURES q Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. q Understand the method of use of safety features and use them properly. q Never remove any safety features.
Page 30: Handrails And Steps
SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. D31PX,D37PX,D39PX,D39EX q Climb up and down from the operator's cab at the machine front. Use the handrails and steps marked by arrows in the diagram on the right when getting on and off the machine.
Page 31: Mounting And Dismounting
SAFETY GENERAL PRECAUTIONS q To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe) to ensure that you support yourself. q Do not grip the control levers when getting on or off the machine.
Page 32: Fire Prevention
SAFETY GENERAL PRECAUTIONS FIRE PREVENTION q Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particu- larly flammable and can be hazardous. To prevent fire, always observe the following: q Do not smoke or use any flame near fuel or oil. q Stop the engine before refueling.
Page 33: Action If Fire Occurs
If ROPS is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the method of repair.
Page 34: Safety At Worksite
SAFETY GENERAL PRECAUTIONS SAFETY AT WORKSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. q When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating. q Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Page 35: Ensure Good Visibility
SAFETY GENERAL PRECAUTIONS q If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone come close to the machine.
Page 36: Be Careful About Asbestos Dust
Do not allow other persons to approach during the opera- tion. q 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. 2-18...
Page 37: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment con- trol 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. q Remove all dirt from the surface of the window glass to ensure a good view.
Page 38: Precautions In Cold Areas
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS IN COLD AREAS q Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
Page 39: Operation
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. q Always fasten your seat belt. q Check the operation of travel, steering and brake systems, and work equipment control system.
Page 40: Traveling On Slopes
SAFETY PRECAUTIONS FOR OPERATION q Avoid traveling over obstacles when possible. If the machine has to travel over an obstacle, keep the work equipment close to the ground and travel at low speed. Never travel over obstacles which make the machine tilt strongly to one side.
Page 41: Operate Carefully On Snow
SAFETY PRECAUTIONS FOR OPERATION OPERATE CAREFULLY ON SNOW q Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 42: Transportation
SAFETY PRECAUTIONS FOR OPERATION TRANSPORTATION 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. Always do as follows. q Perform loading and unloading on firm, level ground only. Ramp Maintain a safe distance from the edge of the road or cliff.
Page 43: Battery
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. q Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 44: Starting With Booster Cable
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. q When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the opera- tor's seat and the other working with the battery).
Page 45: Towing
If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the brake valve sole- noid, 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. 2-27...
Page 46: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG q 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 47: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE q Set safety lock lever (1) and parking lever (2) to the LOCK position. Free Lock Free Lock q Put blocks under the track to prevent the machine from moving. Block TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running.
Page 48: Proper Tools
Do not hit or roll the accumulator, or subject it to any impact. q When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. NO UNAUTHORIZED PERSONNEL INTO AREA Only authorized personnel can service and repair the machine.
Page 49: Work Under The Machine
SAFETY PRECAUTIONS FOR MAINTENANCE WORK UNDER THE MACHINE q If it is necessary to go under the work equipment or the machine to carry out service and maintenance, support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine.
Page 50: Precautions When Using High-Pressure Grease To Adjust Track Tension
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. PRECAUTION WITH HIGH-PRESSURE OIL The hydraulic system is always under internal pressure.
Page 51: Handling High-Pressure Hoses
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 52 SAFETY PRECAUTIONS FOR MAINTENANCE 2-34...
Page 53: Operation
OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 54: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Machine equipped with canopy Machine equipped with cab (1) Blade (7) Track frame (2) Angle cylinder (8) Lift cylinder (3) Radiator mask (9) Idler (4) Canopy (10) Frame (5) Track shoe (11) Cab (6) Sprocket...
Page 55: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Fuel control lever (11) Horn switch Joystick (Steering, directional and gear shift (12) Decelerator pedal lever) Information switch (13) Brake pedal Buzzer cancel switch (14) Safety lock lever Lamp switch (15) Parking lever Monitor panel (16)
Page 56 OPERATION GENERAL VIEW MONITOR PANEL Display panel A (Speed range, Set travel speed, Filter/oil replacement interval lamp Shift mode Indicator) HST oil temperature gauge (10) Warning lamp Engine coolant temperature gauge (11) Engine coolant temperature caution lamp Reverse travel speed indicator (12) Maintenance caution lamp Fuel level gauge...
Page 57: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand the methods of operat- ing equipment and meanings of the displays. FRONT PANEL Emergency caution group Lamp...
Page 58: Check Monitor System
Stop the engine, then turn the starting switch to the ON position and check that the lamps light up for approx. 2 seconds. If they do not light up, please ask your Komatsu distributor to carry out inspec- tion.
Page 59: Emergency Caution Items
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 idling imme- diately and check the trouble spot for necessary actions. These items must be monitored when the engine is running. If there is any abnormality, the caution lamp for the location of the abnormality and warning lamp (A) flash, and the alarm buzzer sounds intermittently.
Page 60 OPERATION EXPLANATION OF COMPONENTS ENGINE COOLANT TEMPERATURE CAUTION LAMP This lamp (2) indicates a raise in the coolant temperature. When the monitor lamp flashes, run the engine at low idling speed until green range of the engine coolant temperature gauge lights. HST OIL TEMPERATURE CAUTION LAMP This lamp (3) warns the operator that the HST oil temperature has gone up.
Page 61: Caution Caution Items
OPERATION EXPLANATION OF COMPONENTS CAUTION CAUTION ITEMS CAUTION If these caution lamps item flash, check and repair the appropriate location as soon as possible. These are items which need to be observed when the engine is running. If any abnormality occurs, the item need- ing immediate repair is displayed.
Page 62 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 63: Meter Group
OPERATION EXPLANATION OF COMPONENTS METER GROUP Engine coolant temperature gauge Display panel A (Speed range, Set travel speed, Shift mode Indicator) HST oil temperature gauge Fuel level gauge Display panel B (Multi-information) Engine preheating pilot lamp Reverse travel speed setting switch Reverse travel speed indicator Shift mode switch ENGINE COOLANT TEMPERATURE GAUGE...
Page 64 OPERATION EXPLANATION OF COMPONENTS HST OIL TEMPERATURE GAUGE NOTICE If the HST oil temperature gauge frequently enters red range (C), check for clogging of the oil cooler. This meter (2) displays the oil temperature in the pump suction piping. Green range (B) should be lighted up during normal opera- tions.
Page 65 OPERATION EXPLANATION OF COMPONENTS REVERSE TRAVEL SPEED INDICATOR This indicator (5) displays the travel speed when traveling in reverse. It is possible to choose the reverse travel speed in five stages according to the nature of the work without changing the forward travel speed.
Page 66 OPERATION EXPLANATION OF COMPONENTS q Examples of the set travel speed compared with the speed range are shown in the table below. Speed ranges- Mode 0.8 km/h 2.7 km/h 4.7 km/h 7.6 km/h -0.7 km/h -0.9 km/h -0.9 km/h 0.8 km/h 3.4 km/h 5.6 km/h 8.5 km/h...
Page 67 OPERATION EXPLANATION OF COMPONENTS DISPLAY PANEL A (SPEED RANGE, SET TRAVEL SPEED, SHIFT MODE INDICATOR) This meter (6) indicates speed range, travel speed, and shift mode. Use the shift mode switch (9) to select the shift mode. Position (A): Quick shift mode Pilot lamp (C) on display panel A lights up.
Page 68 OPERATION EXPLANATION OF COMPONENTS QUICK SHIFT MODE The travel speed is set to the travel speed that matches the general operating load. Operation is easy: each time the shift switch on the steering, directional, and gearshift lever is pressed, the speed switches 1st ↔ 2nd ↔ 3rd. q Each time the UP switch on the steering, directional, and gearshift lever is pressed, the speed switches 1st →...
Page 69 OPERATION EXPLANATION OF COMPONENTS VARIABLE SHIFT MODE The travel speed can be set in 20 stages from 0.8 km/h to 8.5 km/h. In particular, the minimum travel speed is set low so that work such as loading the machine onto a trailer or travel- ing over rough places on the road surface can be carried out more safely.
Page 70 OPERATION EXPLANATION OF COMPONENTS q See the chart below for details of the lighting up of bar graph (G) around the outside circumference and the set travel speed. Gauge Speed Set travel Gauge Speed Set travel Gauge Speed Set travel range Speed range...
Page 71 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 72: Lamps
OPERATION EXPLANATION OF COMPONENTS LAMPS Warning lamp Filter/oil replacement interval lamp WARNING LAMP (Red) NOTICE If alarm buzzer sounds, stop work immediatey 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-informa- tion).
Page 73: Method Of Using Maintenance Mode
OPERATION EXPLANATION OF COMPONENTS After replacing the indicated filter or oil displayed on display panel B (multi-information), reset the time. For details, see “METHOD OF USING OIL AND FILTER MAINTENANCE MODE (3-23)“. The lamp goes out or stops flashing. METHOD OF USING MAINTENANCE MODE To switch from the operation mode to the maintenance mode, turn the buzzer switch to the position and hold it there for at...
Page 74 OPERATION EXPLANATION OF COMPONENTS METHOD OF SELECTING EACH MODE Operating mode (Hold for 2.5 sec) Oil/filter maintenance mode Detailed item display PM clinic auxiliary mode Detailed item display Maintenance mode Fault code display mode Detailed item display Adjustment mode Detailed item display (To oil/filter maintenance mode) 3-22...
Page 75 If the controllers or monitor panel are replaced, the timer for this function will not worl properly. Contact your Komatsu distributor for replacement. In the oil and filter maintenance mode, the replacement inter- vals for oil and filters are displayed on display panel B (multi- information).
Page 76 OPERATION EXPLANATION OF COMPONENTS When the oil or filter has been replaced, select the applicable item, then operate the buzzer cancel switch to The screen will ask if you want to display the replacement his- tory. Operate the information switch to select YES, then operate the buzzer cancel switch to .
Page 77 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 mea- surements, check carefully that the situation is safe. The PM clinic auxiliary mode displays the engine speed or hydraulic pressure on display panel B (multi-informa- tion).
Page 78 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 79 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. 1. Adjusting backlighting of liquid crystal display 2.
Page 80 OPERATION EXPLANATION OF COMPONENTS 5. Adjusting backlighting of display panel B (multi-information) 6. 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 81 OPERATION EXPLANATION OF COMPONENTS 9. Adjusting contrast of liquid crystal display panel B (multi-information) 10. The diagram on the right is the mode for adjusting the con- trast of the liquid crystal display panel B (multi-information). On this screen, operate the buzzer cancel switch to switch to the screen to adjust the contrast.
Page 82: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Lamp switch Horn switch Buzzer cancel switch Room lamp switch (machine equipped with cab) Information switch Wiper switch (machine equipped with cab) Reverse travel speed setting switch (10) Wiper motor breaker reset button (machine equipment with cab) Shift mode switch Starting switch (11)
Page 83 OPERATION EXPLANATION OF COMPONENTS BUZZER CANCEL SWITCH This switch (2) is used to operate control panel B (multi-information) or to stop the alarm buzzer. When the switch is released, it returns automatically to the cen- ter position. When display panel B (multi-information) is in the operation mode q When the alarm buzzer is sounding, turn this switch to position to stop the buzzer.
Page 84 OPERATION EXPLANATION OF COMPONENTS SHIFT MODE SWITCH Use this switch (5) to switch the shift mode. For details, see“DISPLAY PANEL A (SPEED RANGE, SET TRAVEL SPEED, SHIFT MODE INDICATOR) (3-15)“. STARTING SWITCH The switch (6) is used to start and stop the engine. OFF position: At this position, the starting switch key can be inserted and removed.
Page 85 OPERATION EXPLANATION OF COMPONENTS ROOM LAMP SWITCH (Machines equipped with cab) This switch (8) is used to lights up the room lamp. OFF position: Lamps are out ON position: Lamps light up WIPER SWITCH (Machines equipped with cab) This (9) activates the wipers. The wiper switches are as follows.
Page 86 OPERATION EXPLANATION OF COMPONENTS q Wiper and window washer If this is kept pressed to the ON position while the wiper is working, water will be sprayed out. WIPER MOTOR BREAKER RESET BUTTON (Machines equipped with cab) This button (10) is the reset button for the rear window wiper. Use this when the breaker is actuated.
Page 87: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Fuel control lever Blade control lever Joystick (Steering, directional and gear shift Safety lock lever (for blade control lever) lever) Brake pedal parking lever Decelerator pedal FUEL CONTROL LEVER WARNING q Check that the steering and forward-reverse selector lever is in the N (neutral) position, when operat- ing the fuel control lever to the full stroke, while the machine stands.
Page 88 OPERATION EXPLANATION OF COMPONENTS JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) This lever (2) is used to select the direction of travel, to carry out steering, and to carry out counterrotation turns. Forward-reverse shifting Position (a): FORWARD Position (b): REVERSE Position N: Neutral Move to the front to drive forward;...
Page 89 OPERATION EXPLANATION OF COMPONENTS If the operating load increases, the travel speed will slowly decrease and the transmission will shift down. When the load becomes lighter again, the transmission will shift up to the set travel speed. When the transmission automatically shifts down, the speed range display does not change. BRAKE PEDAL WARNING Do not place your foot on this pedal unnecessarily.
Page 90 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER This lever (5) is used to lift, tilt or angle the blade. After the engine is stopped, the blade will not move even if the blade control lever is operated. LIFTING CONTROL (a) RAISE: (b) HOLD: Blade is stopped and held in this position.
Page 91 OPERATION EXPLANATION OF COMPONENTS ANGLING CONTROL Turn the knob to the right or left to angle the blade. (g) LEFT ANGLE (h) HOLD: Blade is stopped and held in this position. (i) RIGHT ANGLE REMARK When performing only angling operation, be sure to set the lever in the neutral (HOLD) position and turn the knob to the right or left.
Page 92 OPERATION EXPLANATION OF COMPONENTS PARKING LEVER WARNING q When parking the machine, always set the parking lever in the LOCK position. q If the parking 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 lever when the machine is moving, except in emergencies.
Page 93: Fuse
OPERATION EXPLANATION OF COMPONENTS FUSE NOTICE Before replacing a fuse, be sure to turn ignition 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.
Page 94: Electric Power Take-Out Adapter
OPERATION EXPLANATION OF COMPONENTS Fuse box (2) Fuse Name of circuit capacity Cab power source (spare) Canopy heater Power port Chassis power source q Cab (machines equipped with cab) Fuse box (3) (Machine equipped with cab) Fuse Name of circuit capacity Radio memory Radio, lamp, cigarette lighter...
Page 95: Door - Open Lock
OPERATION EXPLANATION OF COMPONENTS REMARK Ground the negative wire to the body work or ROPS. Do not ground it to the rubber mounted engine or valves. This will cause failures. If the wire is grounded to a point where there is still paint, the electricity will not flow smoothly, so remove the paint. DOOR - OPEN LOCK (Machines equipped with cab) Use this when your want to keep the door held open.
Page 96: Cap, Cover With Lock
OPERATION EXPLANATION OF COMPONENTS CAP, COVER WITH LOCK Use the starting switch key to open and close the caps and covers. For their locations , see “LOCKING (3-99)“. Insert the key as far as it will go to the shoulder. If the key is turned before it is inserted all the way, it may break.
Page 97: Method Of Opening And Closing Cover With Lock
OPERATION EXPLANATION OF COMPONENTS METHOD OF OPENING AND CLOSING COVER WITH LOCK TO OPEN THE COVER (LOCKED COVER) 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pull- OPEN ing the cover grip. LOCK TO LOCK THE COVER 1.
Page 98: Ashtray
OPERATION EXPLANATION OF COMPONENTS ASHTRAY (Machines equipped with cab) This is on the left side of the operator's seat. Always make sure that you extinguish the cigarette before clos- ing the lid. LUNCHBOX HOLDER BELT (If equipped) This is the place to put your lunchbox. Hold it in position with the belt.
Page 99: Tool Box
OPERATION EXPLANATION OF COMPONENTS TOOL BOX The tool box is inside the battery inspection cover at the rear right. Keep the tools in this box. GREASE PUMP HOLDER Set the grease pump in the grease pump holder clamp at the rear inside the battery box at the rear right, then secure it in position with the rubber band.
Page 100: Car Stereo, Handling
OPERATION EXPLANATION OF COMPONENTS CAR STEREO, HANDLING (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 Time/radio display selector button (13) Seek tuning buttons...
Page 101 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 102 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 103 OPERATION EXPLANATION OF COMPONENTS TAPE EJECT BUTTON This button (7) is used to stop the tape and to eject the cas- sette. 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 104 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 used also for preset button No.5. When it is pressed, “MTL“ appears on the display. 3-52...
Page 105: Metod Of Operation
OPERATION EXPLANATION OF COMPONENTS METOD 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 106 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)
Page 107: Precaution When Using
If the sound cannot be heard, nothing is displayed, or any other abnormality occurs, turn off the power switch and ask your Komatsu distributor, as soon as possible, to carry repairs. q Stow the antenna when traveling in places with low overhead clearance.
Page 108: Air Conditioner, Handling
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER, HANDLING (Machine equipped with cab, air conditioner) EXPLANATION OF PARTS OFF switch Temperature control switch Air conditioner switch Air flow selector switch FRESH/RECIRC selector switch OFF SWITCH When this switch (1) is depressed, the air conditioner stops sending wind.
Page 109 OPERATION EXPLANATION OF COMPONENTS FRESH/RECIRC SELECTOR SWITCH This switch (3) serves to change the air intake port when cool- ing or warming up the cab interior. q Inside air: When switch (A) is depressed, the air condi- tioner takes in air inside the cab. Set the switch to this posi- tion, when strong cooling or warming is desired.
Page 110: Prevention Method Of Entry Of Dust
OPERATION EXPLANATION OF COMPONENTS PREVENTION METHOD OF ENTRY OF DUST Dust may be prevented from entering the cab room by pressur- izing the inside air to be slightly higher than the outside air. When working in a dusty job site or when preventing dust from entering the cab, use this function.
Page 111: Procedure For Replacing Receiver
OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR REPLACING RECEIVER Replace the receiver once every two years. After replacing the receiver, add compressor oil. Turn the receiver at an angle and measure the oil remaining inside the receiver, then add the same amount of oil (Denso Oil 6) to fill the receiver. REMARK Depending on the condition of use, the replacement interval may be shorter.
Page 112: Accumulator, Handling
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 113: Operation
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. q Do not get on or off the machine from the rear. The footing is usually slippery and can hardly be seen well from the operator's seat.
Page 114 OPERATION OPERATION 6. Check for abnormality in handrails, steps, loose bolts. If any abnormality is found, repair it. Tighten any loose bolts. 7. Check for damage to gauges, lamps on instrument panel, loose bolts Check that there is no damage to the panel, gauges and lamps. If any abnormality is found, replace the parts. Clean off any dirt on the surface.
Page 115: Check Before Starting
OPERATION OPERATION CHECK BEFORE STARTING Always check the items in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD COOLANT WARNING q Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.
Page 116 2. Check that all the monitors and gauges light up for approx. 2 seconds and the alarm buzzer sounds for approx. 2 sec. REMARK If the lamps do not light up, there may be a failure or discon- nection in the monitor, please contact your Komatsu distributor. 3-64...
Page 117 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand. Fuel is highly flammable and dangerous.
Page 118 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING Engine parts and oil are at high temperature immediately after the engine is stopped, and will cause seri- ous burns. Wait for the temperature to cool down before starting the operation. 1.
Page 119 OPERATION OPERATION CHECK, CLEAN WATER SEPARATOR This is inside the inspection cover at the left side at the rear of the machine. Water separator (1) separates the water and dirt from the fuel. If float (2) goes above water drain level (3), drain the water as follows.
Page 120 OPERATION OPERATION CHECK DUST INDICATOR 1. Open engine side cover on the left side of machine. 2. If the yellow piston at the display portion of dust indicator (1) becomes red (7.5 kPa), clean the outer element. After cleaning, press the reset button to reset. 3.
Page 121 Check that the head lamp, rear lamp, and instrument lamp light up normally and they are free from stain and dam- age. If the lamps do not light, check for a broken bulb or disconected wire, contact your Komatsu distributor for repairs. 1. Turn the starting switch to the ON position.
Page 122 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 the starting switch to the ON position.
Page 123 OPERATION OPERATION 3. Set the steering, directional and gear shift lever in the REVERSE position. Reverse The alarm must sound immediately at this time. The alarm keeps sounding until the steering, directional and gear shift lever is set to the NEUTRAL or FORWARD position. 3-71...
Page 124: Adjustment
OPERATION OPERATION ADJUSTMENT ADJUST OPERATOR'S SEAT WARNING When adjusting the position of the operator's seat, always set the safety lock lever to the LOCK position to prevent any accidental contact with the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 125 OPERATION OPERATION (D) Seat angle adjustment q Front angle adjustment of seat (5 stages) To raise the front of the seat, apply your weight to the seatback, while pulling up lever (4). To lower the front of the seat, apply your weight to the front of the seat, while pulling up lever (4). q Rear angle adjustment of seat (5 stages) To raise the rear of the seat, stand up on your feet a little, while pulling up lever (5).
Page 126 OPERATION OPERATION 2. After adjusting the seat position, adjust tether belt (1). Tense the tether belt and install it when there is no one sit- ting on the seat. 3. Sit on the seat and hold tongue (4) connected to wind-in mechanism (2) and pull out the belt slowly so that the belt will cover your abdomen sufficiently.
Page 127: Operation And Check Before Starting Engine
OPERATION OPERATION OPERATION AND CHECK BEFORE STARTING ENGINE WARNING When starting the engine, check that the parking lever and safety lock lever are placed securely at the LOCK position. If the work equipment control lever is touched by accident when the engine is started, the work equipment may move unexpectedly and cause serious injury or damage.
Page 128 OPERATION OPERATION 3. Check that the blade control lever (3) is HOLD position. Hold 4. Check that the safety lock lever (4) is locked. Free Lock 3-76...
Page 129: Starting Engine
OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING q Start the engine only after sitting down in the operator's seat. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 130 OPERATION OPERATION 4. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position. 5. Continue to run the engine at idling for 15 seconds after starting. During this time, do not operate the control levers or fuel control lever.
Page 131: Starting In Cold Weather
OPERATION OPERATION STARTING IN COLD WEATHER WARNING q Start the engine only after sitting down in the operator's seat. q 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. q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 132 OPERATION OPERATION 3. Insert the key into starting switch (2) and turn it to the HEAT position. Engine preheating pilot lamp (3) will light Keep it at the HEAT position for the specified preheating time. The preheating times are as shown below. Ambient temperature Preheat time Abave 0°C...
Page 133: Operations And Checks After Starting Engine
Be particularly sure to carry out the warming-up operation thoroughly in cold areas. BREAKING IN THE NEW 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.
Page 134: Starting In Cold Weather
(B): Green range (C): Red range 3. Check that there is no abnormal exhaust gas color, noise or vibration. If any abnormality is found, contact your Komatsu distributor. STARTING IN COLD WEATHER (Ambient temperature below 10°C) After starting the engine, do not immediately start operations. First, carry out the following operations and checks.
Page 135 5. Check that there is no abnormal exhaust gas color, noise or vibration. If any abnormality is found, contact your Komatsu distributor. 6. After carrying out the warming-up operation, to make the temperature of all equipment the same, run the engine at a mid-range speed and travel slowly forward and in reverse.
Page 136: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is stopped abruptly, service life of component parts of the engine may be considerably reduced. Hence do not stop the engine abruptly except in an emergency. If the engine has overheated, do not try to stop it abruptly but run it at medium speed to allow it to cool down gradu- ally, and then stop it.
Page 137: Machine Operation
OPERATION OPERATION MACHINE OPERATION MOVING MACHINE WARNING q When moving machine, check that the area around the machine is safe, and sound the horn before moving. Clear all personnel from the machine and the area. Use extreme care when reversing the machine. Note there is an blind spot behind the machine.
Page 138 Check that the backup alarm sounds when joystick is placed in REVERSE. If the alarm does not sound, please contact your Komatsu distributor. When the steering, directional, and gearshift lever is placed in FORWARD or REVERSE, the machine may deviate slightly to...
Page 139 OPERATION OPERATION 7. Pull fuel control lever (3) to increase engine speed. Low idling 8. Release decelerator pedal (5) slowly and move the machine off. 3-87...
Page 140: Stopping Machine
OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. 1. Depress decelerator pedal (1) and return steering, direc- tional, and gearshift lever (2) to the N position. The machine will stop. Forward Reverse REMARK If it is difficult to stop the machine on a downhill slope using only the decelerator pedal, use brake pedal (3) in addition to the decelerator pedal.
Page 141: Shifting Gears
OPERATION OPERATION SHIFTING GEARS The machine does not have to be stopped to shift gears. Press the shift switch on the knob of steering, directional, and gearshift lever (1) and select the desired speed range. Gear shifting Press the shift switch of the knob of the steering, directional, and gearshift lever to carry out the gearshifting operation.
Page 142: Shifting Between Forward And Reverse
Check that the backup alarm sounds when joystick is placed in REVERSE. If the alarm does not sound, please contact your Komatsu distributor. When the steering, directional, and gearshift lever is placed in FORWARD or REVERSE, the machine may deviate slightly to...
Page 143: Steering Machine
OPERATION OPERATION STEERING MACHINE WARNING q 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 land. q Never make a pivot turn at high speed. NORMAL TURNING To turn the machine while traveling, incline joystick (1) in the direction to turn.
Page 144: Turning While Descending A Slope
OPERATION OPERATION WHEN MAKING PIVOT TURN TO LEFT WHILE TRAVELING When steering the machine, if the lever is operated further from the position where it becomes heavy, the left and right tracks will rotate in opposite directions and the machine will carry out a counterrotation turn.
Page 145: Precautions For Operation
OPERATION OPERATION PRECAUTIONS FOR OPERATION PAY ATTENTION TO GAUGES When the red range lights on the HST oil temperature gauge while operating, reduce the load and wait for the tem- perature to decrease. PERMISSIBLE WATER DEPTH When operating in water, always keep the bottom of carrier roll- ers (1) above the surface of the water.
Page 146: Precautions On Slopes
OPERATION OPERATION PRECAUTIONS ON SLOPES BE CAREFUL OF FUEL LEVEL If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle of the machine or the swaying of the machine. This makes the engine stop, so be careful not to let the fuel level in the fuel tank become too low.
Page 147: 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 148: Cutting Into Hard Or Frozen Ground Or Ditching
OPERATION OPERATION CUTTING INTO HARD OR FROZEN GROUND OR DITCHING For digging and ditch excavation of hard or frozen ground, tilt the blade. Even hard ground can be dug effectively by a tilted or angled blade. FELLING TREES, REMOVING STUMPS NOTICE Do not uproot trees or stumps or fell trees by angling or tilting the blade.
Page 149: Parking Machine
OPERATION OPERATION PARKING MACHINE WARNING q When parking the machine, select flat hard ground. q Avoid parking the machine on a slope. q On slopes, even if steering, directional and gear shift lever is set to the N position, the machine may move slowly down the slope.
Page 150: Check After Finishing Work
OPERATION OPERATION 4. Set safety lock lever (3) in the LOCK position. Free Lock CHECK AFTER FINISHING WORK BEFORE STARTING ENGINE Use the meters and caution lamps to check the engine water temperature, engine oil pressure, fuel level, and HST oil tem- perature.
Page 151: Locking
OPERATION OPERATION LOCKING To prevent vandalism, there are locks at the following places. Places that can be locked with the ignition switch key. q Top cover at front of chassis (1) q Right and left engine side covers (2) q Cab door opener (3) (machine equipped with cab) q Cap with lock (4) q Fuel tank cap q Hydraulic tank cap...
Page 152: Tips For Longer Undercarriage Life
OPERATION METHOD q Select the track shoe that best suits the type of soil to be encountered in service. Please consult your Komatsu distributor when selecting track shoes. q Do not allow shoe slipping to occur during operation. If shoe slipping occurs, reduce load to the blade until slipping stops.
Page 153: Inspection And Repair
Frequent inspection and prompt repair will reduce repair costs. The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per- form periodical inspection and contact the Komatsu distributor in your area when machine has approached repair- able limits and reversing limits.
Page 154 OPERATION OPERATION MEASURING HEIGHT OF GROUSER After taking up slack in track shoes, measure height at center of shoe as shown below. D31,37 q Standard height (h): 47 mm q Repair limits: 20 mm q Standard height (h): 53 mm q Repair limits: 25 mm MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 1.
Page 155: Transportation Means
If it is necessary to remove the cab for transportation, there is danger that the seal may be damaged when remov- ing or installing the cab, so please contact your Komatsu distributor. When installing the cab, please contact your Komatsu distributor, too.
Page 156: Loading, Unloading Work
OPERATION TRANSPORTATION LOADING, UNLOADING WORK WARNING q Since loading and unloading of the machine is dangerous, be extremely careful. q When loading or unloading the machine, operate it slowly with the engine speed low and the speed range at 1st or less. q Use ramps having sufficient width, length, thickness, and strength.
Page 157 OPERATION TRANSPORTATION 4. Set parking lever to the FREE position 5. Use the variable mode to set the speed range to 1st or less, and travel slowly. 6. Set the travel direction toward the ramps and drive slowly. 7. The center of gravity of the machine shifts suddenly at the Free border between the ramps and trailer, and the machine is unbalanced and becomes dangerous.
Page 158 OPERATION TRANSPORTATION SECURING MACHINE WARNING When the edge of the blade protrudes beyond the trailer, angle the blade. NOTICE Always loosen the screw at the rotating portion and set the car radio (machine equipped with cab) antenna facing down. Load the machine onto a trailer as follows: 1.
Page 159 OPERATION TRANSPORTATION UNLOADING WORK 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. Make the slope of the ramps a maximum of 15°.
Page 160: Lifting Machine
The lifting procedure applies to machines with standard specifications. The method of lifting differs according attachments and options actually installed on the machine. For the proper lifting procedures, contact your Komatsu distributor. For details of the weight, see “SPECIFICATIONS (5-2)“.
Page 161: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the ground surface.
Page 162 OPERATION COLD WEATHER OPERATION BATTERY WARNING q The battery generates flammable gas, so do not bring fire or sparks near the battery. q 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 163: 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, always observe the following precautions. q Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rod clean to prevent damage to the seal caused by mud or dirt on the rod surface getting inside the seal together with drops of water.
Page 164: Long-Term Storage
AFTER STORAGE NOTICE If the machine has been stored without the monthly rust prevention operation, consult your Komatsu dis- tributor for service. When using the machine after long-term storage, do as follows before using it. q Wipe off the grease from the hydraulic cylinder rods.
Page 165: Troubleshooting
When returning a towed machine to the jobsite, first check that the necessary repairs and adjustments have been made. For details of the method of towing, please contact your Komatsu distributor. q With this machine, if the engine stops or there is an abnormality in the hydraulic system and the oil pressure in the brake circuit drops, the brake is actuated to prevent the machine from moving.
Page 166: When It Is Possible To Start Engine
OPERATION TROUBLESHOOTING If the machine gets stuck in the mud or a heavy thing needs to be towed, install a towing wire rope to the draw bar pin. WHEN IT IS POSSIBLE TO START ENGINE CAUTION The operator of the machine being towed should always operate the steering so that the machine faces in the direction of the towing line.
Page 167: When Engine Does Not Start
For details of the equipment needed to tow a machine when the engine does not work, please contact your Komatsu distributor. To release the brakes, install a brake release pump on the machine to be towed and connect the hose at the pres- sure side of the pump to the brake valve.
Page 168 OPERATION TROUBLESHOOTING PUMP TEST CAUTION If the operation is carried out without inspecting the hydraulic pump, it may lead to damage of the brake system seal. Always inspect the hydraulic pump before connecting it. 1. Install tee (1) to the discharge portion of the pump, then install oil pressure gauge (2) and rubber hose (3).
Page 169 OPERATION TROUBLESHOOTING CONNECTING PUMP TO MACHINE WARNING q Fit blocks under the tracks to prevent the machine from moving, then release the brake. q Immediately after the engine is stopped, all parts are at high temperature, so do not carry out the oper- ation to install the brake release pump immediately.
Page 170 OPERATION TROUBLESHOOTING 8. Set the brake release pump in front of the operator. RELEASING BRAKE CAUTION When a machine is towed, the brakes must be fully released. If the brakes are partially applied, this may lead to overheating and damage to the brakes. To release the brakes, set the pump pressure to 2.7 to 3.1 MPa (28 to 32 kg/cm²).
Page 171 OPERATION TROUBLESHOOTING OPERATING BRAKE CAUTION To operate the brakes, and open the bypass valve and drain all the oil. The brake system is operated only by opening the bypass valve. If the valve is not at the OPEN position, the brake pedal and parking lever will not work. 1.
Page 172: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING When removing, disconnect the cable from the ground terminal first q It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. q When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position.
Page 173: Remove And Install Battery
OPERATION TROUBLESHOOTING REMOVE AND INSTALL BATTERY 1. Open the battery cover (1), then remove 4 nuts (2) of the battery mounting holder. 2. Before removing battery, remove the ground cable (nor- mally connected to the negetive (-) terminal). If any tool touches between the positive terminal and the chassis, there is danger of sparks being generated.
Page 174: Starting Engine With Booster Cable
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 q When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. q When starting the engine with a booster cable, always wear safety glasses and rubber gloves.
Page 175 OPERATION TROUBLESHOOTING CONNECTING THE BOOSTER CABLE Keep the starting switch of the normal machine and problem machine in the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. 1. Connect one clip of booster cable (A) to the positive (+) ter- minal of the problem machine.
Page 176: When Engine Does Not Stop
4. Installed nut (1) of the stop solenoid and connect rod (2). There is probably a failure or disconnection, so after stopping the engine, contact your Komatsu distributor for repairs. 3-124...
Page 177: Other Trouble
TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even (•Check, repair loose terminals, dis-...
Page 178: Monitor Panel
(If no telephone number is set, dis- plays 0) Note: If an abnormality display appears on display panel B, check the fault code. For details, see “METHOD OF USING FAULT CODE DISPLAY MODE (3-26)“. When contacting your Komatsu distributor, please give the fault code also. 3-126...
Page 179: Chassis
OPERATION TROUBLESHOOTING CHASSIS q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy •Defective adjustment of brake limit (•Adjust, check, repair)
Page 180: Engine
OPERATION TROUBLESHOOTING ENGINE q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure caution lamp •Add oil to specified level, see...
Page 181 MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 182: Guide To Maintenance
KOMATSU GENUINE REPLACEMENT PARTS: Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem- perature. ALWAYS USE CLEAN WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 183 MAINTENANCE GUIDE TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: q Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged. q Clean the radiator core frequently to avoid clogging. q Clean and replace the fuel filter frequently. q Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Page 184 MAINTENANCE GUIDE TO MAINTENANCE CHECKS AFTER INSPECTION AND MAINTENANCE WORK: 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: q Checks after operation (with engine stopped) q Have any inspection and maintenance points been forgotten? q Have all inspection and maintenance items been performed correctly? q Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped...
Page 185: Outline Of Service
When changing the oil, always replace the related filters at the same time. q We recommend you have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor. FUEL q After completing the day's operations, fill the fuel tank to force out any air containing moisture.
Page 186: Coolant
Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair methods.
Page 187: Storing Oil And Fuel
Carry out sampling regularly at fixed intervals. q Do not carry out 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 q Keep indoors to prevent any water, dirt, or other impurities from getting in.
Page 188: Relating To Electric System
External electro-magnetic interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your Komatsu distributor. q When working at the seashore, carefully clean the electric system to prevent corrosion.
Page 189: Wear Parts List
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 190 MAINTENANCE WEAR PARTS LIST Weight Replacement Item Part No. Part Name Q'ty frequency 12F-70-31251 Cutting edge 13.3 D31EX 12F-70-31261 Cutting edge 16.5 Power angle 11G-71-31170 End bit (left and right) power tilt dozer (02090-11055) (Bolt) (19) (02290-11016) (Nut) (19) 12F-70-31281 Cutting edge 21.9 D31PX...
Page 191: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS AMBIENT Kind of TEMPERATURE Reservoir Type fluid 0°C 40°C SAE 30 -20° C 10°...
Page 192 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add sin- gle grade oil that matches the temperature range in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Page 193 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter, one EO15-40CD season type) Diesel sigma S super dieselmulti- AGIP Rotra MP GR MU/EP...
Page 194 MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.)
Page 195: 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 196: Periodic Replacement Of Safety Critical Parts
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the critical parts. SAFETY CRITICAL PARTS No. Safety critical parts for periodic replacemen...
Page 197: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART WHEN REQUIRED Check, clean and replace air cleaner element ....................4-194 Clean inside of cooling system.......................... 4-234 Check track tension............................4-254 Check and tighten track shoe belt........................4-274 Check electrical intake air heater ........................4-274 Reverse and replace end bits and cutting edges ....................
Page 198: Every 2000 Hours Service
MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 2000 HOURS SERVICE Change oil in hydraulic tank, replace oil filter cartridge and clean suction strainer ........... 4-534 Clean, check turbocharger ..........................4-554 Check vibration damper ............................ 4-554 Check alternator, starting motor ........................4-554 Check engine valve clearance, adjust....................... 4-554 EVERY 4000 HOURS SERVICE Check water pump ............................
Page 199: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING q If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. q When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 200 MAINTENANCE SERVICE PROCEDURE CLEANING OR REPLACING OUTER ELEMENT 1. Open engine side cover on the left side of machine. 2. Remove three clips (2), then remove dust cup (3). NOTICE Never remove inner element (5). If it is removed, dust will enter and cause engine trouble.
Page 201 MAINTENANCE SERVICE PROCEDURE 8. If small holes or thinner parts are found on the element when it is checked by shining a light through it after clean- ing, replace the element. NOTICE When cleaning the element, do not hit or beat it against anything.
Page 202 MAINTENANCE SERVICE PROCEDURE REPLACING ELEMENT 1. Open engine side cover on the left side of machine. 2. Remove three clips (2), then remove dust cup (3). 3. Remove outer element (4). Do not remove inner element (5) at this time, however. NOTICE When cleaning the dust cup, do not remove evacuator valve (6).
Page 203: Clean Inside Of Cooling System
MAINTENANCE SERVICE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM WARNING q Just after the engine is stopped, the cooling water is still hot and the internal pressure in the radiator is still high. If the radiator cap is removed under this condition, you may scald yourself. Accordingly, wait until the temperature goes down, then loosen the cap slowly to release the pressure.
Page 204 If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once. Use city water for the coolant. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 205: Check Track Shoe Tension, Adjust
1 turn. Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. 4-25...
Page 206 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. 1. Loosen plug (1) gradually to release the grease.
Page 207: Check And Tighten Track Shoe Bolts
180° ± 10° 180° ± 10° CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. 4-27...
Page 208: Reverse And Replace End Bits And Cutting Edges
MAINTENANCE SERVICE PROCEDURE REVERSE AND REPLACE 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 safety lock lever.
Page 209: Check Idler Oil Level, Add Oil
Tighten plug (4). 3. If any oil does not flow out when plug (4) is removed, the quantity of oil is insufficient. In this case, ask your Komatsu distributor for repair. 4. Install guide plate (2) and shim (3) with bolt (1).
Page 210: Adjust Play In Center Ball
MAINTENANCE SERVICE PROCEDURE ADJUSTMENT 1. Move the machine by 1 to 2 m on a level place, then mea- sure clearance A between the track frame and guide plate (at four places of both sides, inside, and outside). 2. If the clearance A exceeds 4.0 mm, loosen bolt (1), and pull out the shim to adjust the clearance at one end to 0.5 to 1.0 mm.
Page 211: Check Door Lock Striker
MAINTENANCE SERVICE PROCEDURE CHECK DOOR LOCK STRIKER (Machines equipped with cab) If the wear of the door lock striker exceeds 0.5 mm, replace the striker. If it is used at it is, the play will increase and this may result in breakage of the hinge or door lock. Striker CHECK, ADJUST AIR CONDITIONER (Machines equipped with cab)
Page 212 MAINTENANCE SERVICE PROCEDURE q No bubbles in refrigerant flow: Suitable (A) q Some bubbles in flow Sight glass (bubbles pass continuously): Lack of refrigerant (B) q Colorless, transparent: No refrigerant (C) REMARK When there are bubbles, the refrigerant gas level is low, so Receiver contact your refrigerant dealer to have refrigerant added.
Page 213: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE SERVICE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machines equipped with cab) Do this when no more window washer fluid is sprayed out. Open cover (1), check the level of the fluid in window washer tank (2), and if it is low, add automobile window washer fluid. When adding fluid, be careful not to let any dirt or dust get in.
Page 214: Procedure For Bleeding Air In Hydraulic System
MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM When the hydraulic oil filter elements or strainers are cleaned or replace, or when any hydraulic component has been repaired or replaced, or when a hydraulic piping has been disconnected, bleed air from the hydraulic oil cir- cuit.
Page 215: Procedure For Releasing Internal Pressure Of Hydraulic System
MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM WARNING q The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting. If the pressure is not released, high pressure oil may spurt out and cause serious personal injury.
Page 216: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see “CHECK BEFORE STARTING (3-63)“ in the OPERATION section. q Check coolant level, add coolant q Checking with monitor q Check fuel level, add fuel q Check oil level in engine oil pan, add oil q Check, clean water separator q Check dust indicator q Check oil level in hydraulic tank, add oil...
Page 217: Every 50 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE DRAIN WATER, SEDIMENT FROM FUEL TANK Carry out this check before operating the machine. q Prepare a container to catch the fuel that is drained. 1. Open drain valve (1) at the bottom inside the inspection cover on the left side at the rear of the machine and drain the water and sediment accumulated at the bottom together with fuel.
Page 218: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATING NOTICE If dirt or sand is found sticking due to work in the soft ground, carry out greasing every 10 hours of opera- tion.
Page 219 MAINTENANCE SERVICE PROCEDURE (8) Frame center ball (1 place) (9) Rod pin (2 places) q D39EX,PX (1) Lift cylinder bottom pin (2 places) (2) Lift cylinder head pin (2 places) (3) Angle cylinder bottom pin (2 places) (4) Frame mounting pin (2 places) (5) Angle cylinder head pin (2 places) (6) Tilt cylinder head pin (1 place) (7) Tilt cylinder bottom pin (1 place)
Page 220: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING q The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. q If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.
Page 221: Check Level Of Battery Electrolyte
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. 4-41...
Page 222 If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. 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. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
Page 223: Check Brake Performance
MAINTENANCE SERVICE PROCEDURE CHECK BRAKE PERFORMANCE WARNING If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately. Before starting the engine, check that the area around the machine is safe, then do as follows.
Page 224: Clean Air Conditioner Air Filter (Fresh/Recirc Filter)
MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (Machines equipped with cab) 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 225: Every 500 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 500 HOURS SERVICE Maintenance for every 50 and 250 hours service should be carried out at the same time. REPLACE FUEL FILTER CARTRIDGE WARNING q Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter.
Page 226 MAINTENANCE SERVICE PROCEDURE METHOD OF USING AUTOMATIC AIR BLEED MECHANISM (If equipped) WARNING The engine will start, so check carefully that the area around the engine is safe before cranking it. It is possible to bleed the air from the fuel circuit simply by rotating the starting motor with the starting switch. Bleed the air as follows;...
Page 227 MAINTENANCE SERVICE PROCEDURE 5. Return the key in the starting switch to the ON position and wait for approx. 30 seconds. 6. Turn the key in the starting switch to START and hold it there for 20 seconds. When this is done, the starting motor will be actuated for approx. 2 seconds and then will stop, but the engine will turn.
Page 228: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
(P) slowly to drain the oil. Be careful not to get the oil on yourself. 3. Check the drained oil, and if there are excessive metal par- ticles or foreign material, please contact your Komatsu dis- tributor. 4. Tighten drain valve (P).
Page 229: Replace Corrosion Resistor Cartridge
4. Apply engine oil to the sealing surface of a new cartridge, then install it to the filter holder. 5. When installing, screw in cartridge until seal comes in contact with sealing surface, then tighten approx. 2/3 turn. 6. Open valves (1) (2 places). Use Komatsu genuine cartridge. 4-49...
Page 230: Clean, Check Radiator Fins And Oil Cooler Fins
MAINTENANCE SERVICE PROCEDURE CLEAN, CHECK RADIATOR FINS AND OIL COOLER FINS WARNING If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard of serious injury. Always use safety glasses, dust mask, or other protective equipment.
Page 231: Every 1000 Hours Service
68.6 ± 9.8 N·m (7 ± 1 kgf·m) CHECK FAN BELT TENSION, ADJUST Since inspection and replacement of the fan belt require special tools, contact your Komatsu distributor. REMARK The machine is equipped with an auto tensioner, so there is no need to adjust the tension.
Page 232: Check Play Of Turbocharger Rotor
MAINTENANCE SERVICE PROCEDURE CHECK PLAY OF TURBOCHARGER ROTOR Contact your Komatsu distributor to have the rotor play checked. CHECK FOR LOOSE ROPS MOUNT BOLTS (If equipped) Check that the bolts are not loose and that there is no damage. If any bolt is loose, tighten it to the following torque.
Page 233: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER WARNING q The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 234 13. After the packing surface of the cartridge touches the sealing surface of the filter holder, tighten the cartridge further by about 2/3 turns. Use Komatsu genuine cartridge. 14. Refill the specified quantity of oil through oil filler (F). 15. After adding oil, check that the oil is at the correct level.
Page 235: Clean, Check Turbocharger
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced. CHECK ALTERNATOR, STARTING MOTOR The brushes mat be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspec- tion and repairs.
Page 236: Every 4000 Hours Service
Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be carried out at the same time. CHECK WATER PUMP Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any abnormality is found, please contact your Komatsu distributor for repairs or replacement. 4-56...
Page 237: Specifications
SPECIFICATIONS...
Page 238 SPECIFICATIONS With power angle power tiltdozer and ROPS cab Item Unit D31EX-21 D31PX-21 Machine weight 7,130 7,650 Name of engine Komatsu SAA4D102E-2 diesel engine Engine horsepower kW (HP)/rpm 56 (75)/2,000 Overall length 4,015 3,995 (Not including antenna) 2,700 2,700 Overall height...
Page 239 SPECIFICATIONS With power angle power tiltdozer and ROPS cab Item Unit D39EX-21 D39PX-21 Machine weight 8,820 9,200 Name of engine Komatsu SAA4D102E-2 diesel engine Engine horsepower kW (HP)/rpm 71 (95)/2,000 Overall length 4,200 4,200 (Not including antenna) 2,770 2,770 Overall height...
Page 240 SPECIFICATIONS SPECIFICATIONS...
Page 241: Attachments, Options
ATTACHMENTS, OPTIONS WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 242: General Precautions
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 distribu- tor first.
Page 243: Handling Hydraulic Ripper
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER HANDLING HYDRAULIC RIPPER q This ripper is applicable for the D31EX and D37EX and D39EX. GENERAL VIEW Support Shank Hydraulic cylider Point Beam...
Page 244: Explanation Of Components
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER WARNING When carrying out inspection or maintenance of the machine, or when parking the machine, lower the rip- per to the ground and set the safety lock lever to the LOCK position. This lever is used to operate the ripper.
Page 245: Operation
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER OPERATION CHECK BEFORE STARTING ENGINE, ADJUST WALK-AROUND CHECK 1. Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the rivets. If any abnormality is found, replace or repair. PRECAUTIONS WHEN OPERATING q Travel in low speed and lower the ripper gradually when starting to move the machine off.
Page 246: Troubleshooting
HANDLING HYDRAULIC RIPPER TROUBLESHOOTING OTHER TROUBLE q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Slow ripper raising and function, •Improper hydraulic oil...
Page 247: Deluxe Seat
ATTACHMENTS, OPTIONS DELUXE SEAT DELUXE SEAT WARNING When adjusting the position of the operator's seat, always set the safety lock lever to the LOCK position to prevent any accidental contact with the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 248 ATTACHMENTS, OPTIONS DELUXE SEAT (D) Height adjustment of seat q Turn lever (4) to adjust the height of the seat. q If the lever is turned clockwise, the seat is heightened. If the former is turn counterclockwise, the latter is low- ered.
Page 249: Headrest
ATTACHMENTS, OPTIONS HEADREST HEADREST Removal of headrest Pull up the headrest. REMARK The headrest cannot be fixed to halfway.
Page 250: Equipping Fire Extinguisher And First-Aid Kit
The fire extinguisher and the first-aid kit can be installed to the positions shown in the following illustration. Equipping the fire extinguisher and the first-aid kit at the illustrated position needs brackets (option). For the brack- ets, please contact your Komatsu distributor. When installing a fire extinguisher, install it in the position shown in the diagram.
Page 251 INDEX...
Page 252 INDEX...
Page 253 INDEX INDEX <A> EXPLANATION OF COMPONENTS ....6-4 GENERAL VIEW..........6-3 ACCUMULATOR, HANDLING......3-60 MAINTENANCE ..........6-6 AIR CONDITIONER, HANDLING ......3-56 OPERATION ............. 6-5 ASHTRAY ............3-46 TROUBLESHOOTING ........6-6 HEADREST ............6-9 <C> CAP, COVER WITH LOCK ........3-44 <I>...
Page 254 INDEX <W> PRECAUTIONS WHEN REMOVING WORK EQUIPMENT ..........3-103 WEAR PART LIST ..........4-9 PRODUCT IDENTIFICATION NUMBER (PIN)/ WEAR PARTS LIST ..........4-9 MACHINE SERIAL NO. PLATE ......1-7 WORK POSSIBLE USING BULLDOZER .... 3-95 <R> RELATING TO ELECTRIC SYSTEM.....4-8 REMOVING CAB ..........3-103 <S>...
Page 255 COLOPHON...

This manual is also suitable for:

D31px-21 D37ex-21 D39px-21 D37px-21 D39ex-21

Komatsu D31EX-21 Operation & Maintenance Manual

Foreword

Safety

Operation

Maintenance

Maintenance

Specifications

Attachments, Options

Quick Links

Troubleshooting

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Questions and answers

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Summary of Contents for Komatsu D31EX-21