Page 2 FOREWORD...
Page 3 If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and speciffications that are necessary for use in your country.
Page 4 FOREWORD FOREWORD...
Page 5 FOREWORD FOREWORD...
Page 6: 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 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
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following works: Dozing Smoothing Cutting into hard or frozen ground or ditching. Felling trees, removing stumps See the section "WORK POSSIBLE USING BULLDOZER (PAGE 3-108)" 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. MACHINE SERIAL NO. PLATE AND POSITION Under the front of the console box on the right side of the operator's seat.
Page 10: Emission Control Information Label
FOREWORD NECESSARY INFORMATION EMISSION CONTROL INFORMATION LABEL Located on the top of the air cleaner mounting bracket on the left of the machine. EPA: Environmental Protection Agency, U.S.A. BLADE SERIAL NO. PLATE POSITION This is located at the right side of blade back surface. RIPPER SERIAL NO.
Page 11: Position Of Service Meter
FOREWORD NECESSARY INFORMATION POSITION OF SERVICE METER This is at the left upper part of the monitor panel. TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Distributor name Address Service Personal Phone/Fax 1-10...
Page 12: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD................................. 1-2 SAFETY INFORMATION............................1-5 INTRODUCTION..............................1-7 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE............... 1-7 NECESSARY INFORMATION ..........................1-8 MACHINE SERIAL NO. PLATE AND POSITION ..................1-8 ENGINE SERIAL NO. PLATE AND POSITION..................1-8 EMISSION CONTROL INFORMATION LABEL ..................1-9 BLADE SERIAL NO.
Page 13 FOREWORD CONTENTS EXPLANATION OF COMPONENTS........................3-6 FRONT PANEL............................3-7 SWITCHES ............................... 3-24 CONTROL LEVERS, PEDALS, DIAL ....................... 3-28 DUST INDICATOR ........................... 3-35 POWER SOURCE ............................ 3-35 FUSE BOX..............................3-36 DOOR-OPEN LOCK ..........................3-38 SASH GLASS INTERMEDIATE LOCK..................... 3-38 HOT AND COOL BOX ..........................3-39 DOOR POCKET ............................
Page 14 FOREWORD CONTENTS LONG TERM STORAGE..........................3-128 BEFORE STORAGE..........................3-128 DURING STORAGE ..........................3-128 AFTER STORAGE..........................3-128 TROUBLESHOOTING............................3-129 AFTER RUNNING OUT OF FUEL......................3-129 METHOD OF TOWING MACHINE ......................3-130 DISCHARGED BATTERY ........................3-131 OTHER TROUBLE ..........................3-135 MAINTENANCE GUIDE TO MAINTENANCE ..........................4-2 OUTLINE OF SERVICE............................
Page 15 FOREWORD CONTENTS ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS ..........................6-2 PRECAUTIONS RELATED TO SAFETY ....................6-2 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS............... 6-4 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS.............. 6-4 HANDLING HEADREST ............................6-5 HANDLING REVERSIBLE FAN ........................... 6-6 REVERSING REVERSIBLE FAN ....................... 6-6 HANDLING CAP WITH LOCK ..........................
Page 16: Safety
SAFETY WARNING Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precaustions strictly.
Page 17 SAFETY SAFETY SAFETY SAFETY LABELS..............................2-4 POSITIONS OF SAFETY PICTOGRAMS ....................... 2-5 SAFETY LABELS............................. 2-6 GENERAL PRECAUTIONS ..........................2-10 SAFETY RULES ............................2-10 IF ABNORMALITIES ARE FOUND ......................2-10 CLOTHING AND PERSONAL PROTECTIVE ITEMS ................2-10 FIRE EXTINGUISHER AND FIRST AID KIT .................... 2-10 SAFETY FEATURES ..........................
Page 18 SAFETY SAFETY PRECAUTIONS FOR OPERATION ........................2-19 STARTING ENGINE ............................2-19 CHECKS BEFORE STARTING ENGINE ....................2-19 PRECAUTIONS WHEN STARTING......................2-20 PRECAUTIONS IN COLD AREAS ......................2-20 OPERATION..............................2-21 CHECKS AFTER OPERATION ........................ 2-21 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE ..........2-21 PRECAUTIONS WHEN TRAVELING.......................
Page 19: 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 20: Positions Of Safety Pictograms
SAFETY SAFETY LABELS POSITIONS OF SAFETY PICTOGRAMS...
Page 21: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Precautions for operation, inspection and mainte- (2) Precautions when traveling in reverse nance (09651-A06411) (09802-B0750) (3) Precautions for leaving the operator's seat (4) Precautions for high-temperature hydraulic oil (09654-B0641) (09653-A0481)
Page 22 SAFETY SAFETY LABELS (5) Precautions for check and adjust track tension (6) Precautions for handling accumulator (09657-A0881) (09659-A057B) Safety label is attached on the back side of the inspection cover of the track frame. (7) Precautions for use of seat belt (8) Warning for ROPS (195-98-12940) (09620-30200)
Page 23 SAFETY SAFETY LABELS (9) Precautions for handling electric wires (10) Precautions for avoiding falling down (09808-A0881) (09805-C0881) (11) Caution for engine running (12) Caution for approach when machine moving (09667-A0481) (09806-B1201)
Page 24 SAFETY SAFETY LABELS (13) Precautions for high voltage (7872-10-1600)
Page 25: 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 when operating or performing maintenance on the machine. 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 26: Safety Features
SAFETY GENERAL PRECAUTIONS SAFETY FEATURES Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition. KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation.
Page 27: Handrails And Steps
SAFETY GENERAL PRECAUTIONS When leaving the machine, always lower the work equip- ment completely to the ground, set safety lock lever and brake lock lever securely to the LOCK position, then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place.
Page 28: Mounting And Dismounting
SAFETY GENERAL PRECAUTIONS MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine. If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.
Page 29: Prevention Of Burns
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 radi- ator cap by hand before starting the operation.
Page 30: Action If Fire Occurs
Komatsu distributor. 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. 2-15...
Page 31: Precautions For Attachments
Any modification mode without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications made without authorization from Komatsu. SAFETY AT WORKSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Page 32: Working On Loose Ground
SAFETY GENERAL PRECAUTIONS WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over.
Page 33: Ventilation For Enclosed Areas
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. 2-18...
Page 34: 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. Completely remove all flammable materials accumulated around the engine and battery, and remove all dirt from the window glasses, mirrors, lights, hand rails, and steps.
Page 35: Precautions When Starting
SAFETY PRECAUTIONS FOR OPERATION Check that there are no persons or obstacles above, below, or in the area around the machine. PRECAUTIONS WHEN STARTING When starting the engine, sound the horn as a warning. Start and operate the machine only while seated. Do not allow anyone apart from the operator to ride on the machine.
Page 36: 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. Always fasten your seat belt. Check the operation of travel, steering and brake systems, and work equipment control system.
Page 37: Precautions When Traveling
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING Never turn the key in the starting switch to the OFF position while traveling. If the engine stops while traveling, steering mechanism does not function, and it results in dangerous situation. In this case, immediately depress the brake pedal to stop the machine.
Page 38: Traveling On Slopes
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 slopes, keep the blade 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 39: Parking Machine
SAFETY PRECAUTIONS FOR OPERATION When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and use the engine as a brake while appling the foot brake intermittently (depress the brake intermittently several times). If necessary, lower the blade to the ground to stop the machine. 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...
Page 40: 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. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of the road or cliff.
Page 41: 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. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 42: 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. 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 43: Towing
If your machine is towed by another machine, stop the engine and release the brake. Please contact your Komatsu distributor to have the brake released. It is dangerous to tow a machine on a slope, so choose a place where there is a gradual slope.
Page 44: Precautions For Maintenence
SAFETY PRECAUTIONS FOR MAINTENENCE PRECAUTIONS FOR MAINTENENCE 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 45: Stop Engine Before Carrying Out Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENENCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground and stop the engine.
Page 46: Proper Tools
Do not weld any boss to the accumulator. When disposing the accumulator, it is necessary to release the gas from the accumulator, so please con- tact your Komatsu distributor. NO UNAUTHORIZED PERSONNEL INTO AREA Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
Page 47: Attachments
SAFETY PRECAUTIONS FOR MAINTENENCE 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. And take steps to prevent unauthorized persons from entering the storage area.
Page 48: Repair Welding
SAFETY PRECAUTIONS FOR MAINTENENCE REPAIR WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with a proper equip- ment. There is a hazard of fire or electrocution when carrying out welding, so never allow any unqualified person- nel to carry out welding.
Page 49: Precaution With High-Pressure Oil
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 50: Waste Material
SAFETY PRECAUTIONS FOR MAINTENENCE 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.
Page 51: Operation
OPERATION WARNING Please read and make sure that you understand the SAFETY section before reading this section.
Page 52: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Blade Multi ripper Blade tilt cylinder Ripper lift cylinder Blade lift cylinder Sprocket (10) Track frame Track shoe (11) Frame Ripper tilt cylinder (12) Idler...
Page 53: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Machine equipped with cab Monitor panel specification Cigarette lighter Brake pedal Fuel control dial (10) Deceleraion pedal Steering, directional and gear shift lever (11) Blade control lever Air conditioner panel or heater panel (12) Horn switch Buzzer cancel switch (13) Ripper control lever...
Page 54 OPERATION GENERAL VIEW Machine equipped with canopy Monitor panel specification Cigarette lighter Deceleration pedal Fuel control dial (10) Blade control lever Steering, directional and gear shift lever (11) Horn switch Buzzer cancel switch (12) Ripper control lever Head lamp switch (13) Pin puller control switch (if equipped) Rear lamp switch (14) Safety lock lever...
Page 55 OPERATION GENERAL VIEW Display panel A HSS charge pressure caution lamp (Speed range and engine speed display) Engine preheating pilot lamp Power train oil temperature (10) HSS oil temperature caution lamp Engine cooling water temperature gauge (11) Fuel gauge Charge level monitor (12) Display panel B (Service meter) Engine oil pressure monitor (13) Room lamp switch (Machine equipped with cab)
Page 56: Explanation Of Components
To carry out suitable operations correctly and safely,it is important to understand fully the methods of operating the equipment and the meanings of the displays. Before reading the explanation of components,please read the table below to check what equipment is installed to your machine. D155AX-5 Equipment Canopy Monitor panel Air conditioner panel —...
Page 57: Front Panel
OPERATION EXPLANATION OF COMPONENTS FRONT PANEL MONITOR PANEL Caution Items Meter Display Portion Emergency Stop Items Monitor Switches ("SWITCHES (PAGE 3-24)") A. Caution items (See "CAUTION ITEMS (PAGE 3-9)") CAUTION If these monitor items flash, check and repair the appropriate location as soon as possible. These are items which need to be observed while the engine is running.
Page 58 OPERATION EXPLANATION OF COMPONENTS C. Meter Display Portion (See "METER DISPLAY PORTION (PAGE 3-12)") This portion consists of pre-heating pilot lamp, power train oil temperature gauge, engine water temperature gauge, fuel gauge, service meter and display. D. Monitor switches (See "SWITCHES (PAGE 3-24)") This select working mode, travel speed and time setting of clock.
Page 59 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If the warning monitor flashes or lights up, carry out inspection and maintenance of the appropriate point as soon as possible. If the problem is not corrected, it may lead to failure of the machine. These are items which need to be observed when the engine is running.
Page 60 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEMS CAUTION If any monitor lamp flashes, stop the engine or run it at a low idling speed,and repair it immediately. These items need to be observed while the engine is running. If any abnormality occurs, items which need to be repaired immediately are displayed.
Page 61 If there is any abnormality, stop the engine immediately and contact your Komatsu distributor. HSS OIL TEMPERATURE CAUTION LAMP This lamp (5) warns of any rise in the oil temperature at the HSS monitor outlet port.
Page 62 If they do not light up, please ask your Komatsu distributor to check them. The meter display portion consists of the engine water temperature gauge, power train oil temperature gauge, fuel gauge, service meter, and preheating pilot lamp.
Page 63 OPERATION EXPLANATION OF COMPONENTS POWER TRAIN OIL TEMPERATURE GAUGE This gauge (2) indicates the oil temperature of the torque con- verter outlet. If the temperature is normal during operation, the green range will light. If the red range lights up during operation,move the Fuel con- trol dial to lower the engine speed to approx.
Page 64 OPERATION EXPLANATION OF COMPONENTS DISPLAY PANEL A (SPEED RANGE AND ENGINE SPEED DISPLAY) Meter (5) displays the transmission speed range being used on the machine and engine speed. When the transmission is in 1st FORWARD, the display shows F1, and when it is in 1st REVERSE, the display shows R1.
Page 65 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER PANEL (MACHINES EQUIPPED WITH CAB, AIR CONDITIONER) FRESH/RECIRC selector lever Temperature control lever Air condition switch Starting switch Blower switch For details of handling levers and switches (1) to (4) below, see "HANDLING AIR CONDITIONER (PAGE 3-54)". FRESH/RECIRC SELECTOR LEVER This lever (1) changes the air intake port used when cooling or heating.
Page 66 OPERATION EXPLANATION OF COMPONENTS AIR CONDITION SWITCH When the switch (2) is pressed and the blue lamp lights up, the cooling function is actuated.Use this switch for cooling or dehu- midifying. BLOWER SWITCH This swich (3) acts as the wind flow control switch and main switch when cooling or heating.
Page 67 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (5) is used to start the engine. OFF position: OFF The key can be inserted or withdrawn. The switches for the electric system are all turned off and the engine is stopped. ON position: ON In this position, electric current flows in the charging and lamp circuits.
Page 68 OPERATION EXPLANATION OF COMPONENTS HEATER PANEL (MACHINES EQUIPPED WITH CAB, HEATER) FRESH/RECIRC selector lever Temperature control lever Blower switch Starting switch For details of handling switches (1) to (3) below, see "HANDLING HEATER (PAGE 3-58)". FRESH/RECIRC SELECTOR LEVER This lever (1) changes the air intake port used when heating. RECIRC: Move lever to left to suck in air inside cab.
Page 69 OPERATION EXPLANATION OF COMPONENTS BLOWER SWITCH This switch (2) acts as the wind flow control switch and main switch when heating. The air flow can be set to three stages: 1 (LOW), 2 (MEDIUM) , 3 (HIGH). If the switch is set to 0, the power is switched off and the heater stops.
Page 70 OPERATION EXPLANATION OF COMPONENTS SWITCH PANEL (MACHINES EQUIPPED WITH CAB) (MACHINES EQUIPPED WITH CANOPY) Head lamp switch Buzzer cancel switch Rear lamp switch Starting switch (Machine equipped with canopy) 3-20...
Page 71 OPERATION EXPLANATION OF COMPONENTS HEAD LAMP SWITCH This switch (1) lights up the head lamps. OFF position: Lamps are out ON position: Lamps light up REAR LAMP SWITCH This switch (2) lights up the rear lamps. OFF position: Lamps are out ON position: Lamps light up BUZZER CANCEL SWITCH...
Page 72 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch is used to start the engine. OFF position: OFF At this position, the starting switch key can be inserted or removed. When the switch is turned to this position, the electri- cal circuits are switched off. ON position: ON In this position, electric current flows in the charging and lamp circuits.
Page 73 OPERATION EXPLANATION OF COMPONENTS ALARM LAMPS Alarm lamp on machine equipped with cab Alarm lamp on machine equipped with canopy NOTICE If the alarm buzzer sounds, immediately stop the operation, then check and repair the corresponding por- tion. ALARM LAMPS The alarm lamps (1) and (2) flash when the following caution lamps flash.
Page 74: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES The sketch shows the D155AX-5 (with cab, monitor panel specification). Horn switch Wiper switch (machines equipped with cab) Room lamp switch (machines equipped with cab) (5) Additional working lamp switch Cigarette lighter (machines equipped with cab)
Page 75 OPERATION EXPLANATION OF COMPONENTS ROOM LAMP SWITCH (MACHINES EQUIPPED WITH CAB) This switch (2) lights up the room lamp. ON position: Lamp lights up OFF position: Lamp is out CIGARETTE LIGHTER (MACHINES EQUIPPED WITH CAB) This switch (3) is used to light igarettes. When the cigarette lighter is pushed in, it will return to its origi- nal position after a few seconds, so take it out to light your cig- arette.
Page 76 OPERATION EXPLANATION OF COMPONENTS Wiper only If this is switched on, the wiper will start. Wiper and window washer If this is kept pressed to the ON position while the wiper is working,water will be sprayed out. ADDITIONAL WORKING LAMP SWITCH (MACHINES EQUIPPED WITH CAB) (OPTION) This switch (5) is used to turn on the additional working lamp.
Page 77 OPERATION EXPLANATION OF COMPONENTS REMARK When installing the cab, check the colors of the washer tank and window washer hoses, and be sure to connect correctly. When installing the cab, please contact your Komatsu dis- tributor for installation. 3-27...
Page 78: Control Levers, Pedals, Dial
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS, DIAL Fuel control dial Safety lever Joystick (Steering, directional and gear shift lever) (for blade control lever, ripper control lever) Brake pedal Blade control lever Deceleration pedal Ripper control lever Parking lever Pin puller control switch (if equipped) FUEL CONTROL DIAL This dial (1) is used to control the engine speed and output.
Page 79 OPERATION EXPLANATION OF COMPONENTS JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) This lever (2) is used to switch between forward and reverse to steer and gear shift the machine or carry out counterrotation turns. Switching between forward and reverse Position (a) : FORWARD Position (b) : REVERSE Position N : Neutral Steering operations...
Page 80 OPERATION EXPLANATION OF COMPONENTS For details of the maximum speed at each speed range, see "SPECIFICATIONS (PAGE 5-2)". When gear shifting operation is carried out, the display panel A will display the used speed range. 1st: F1, R1, or N1 is displayed 2nd: F2, R2, or N2 is displayed 3rd: F3, R3, or N3 is displayed Counterrotation turn...
Page 81 OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING Do not place your foot on this pedal unnecessarily. Depress the pedal (3) to apply the right and left brakes. DECELERATION PEDAL WARNING Do not place your foot on this pedal unnecessarily. When passing over the top of a hill or when a load is dumped over a cliff, the load is suddenly reduced, so there is danger that the travel speed will also increase suddenly.
Page 82 OPERATION EXPLANATION OF COMPONENTS SAFETY LEVER (FOR BLADE CONTROL LEVER, RIPPER CONTROL LEVER) WARNING When standing up from the operator's seat, always set the safety lever securely to the LOCK position. If the blade control and ripper control levers are not locked and are touched by accident, it may lead to serious injury or damage.
Page 83 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER (POWER TILTDOZER) This lever (7) is used to raise 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 When released from FLOAT position, this lever will not return to HOLD position, so it must be moved back by...
Page 84 OPERATION EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER This lever (8) is used to operate the ripper. (a) RAISE (b) HOLD: Ripper is stopped and held in the same position. (c) LOWER (A) Digging angle reduced: Cutting angle (α) becomes smaller. (B) Digging angle increased: Cutting angle (α) becomes larger.
Page 85: Dust Indicator
OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR This device indicates that the air cleaner element is clogged. For details on how to lean the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-25)". POWER SOURCE The cigarette lighter socket can be used as a power source. The capacity of the cigarette lighter power source is 120 W (24V x 5A).
Page 86: Fuse Box
OPERATION EXPLANATION OF COMPONENTS FUSE BOX NOTICE Before replacing a fuse, be sure to turn off the starting switch. 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 87 OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND NAME OF CIRCUIT Fuse box (1) Fuse capacity Circuit Remarks 15 A Horn, pin puller 15 A Engine 20 A Rear lamp 20 A Front lamp 10 A Controller,HSS Monitor pannel, 15 A alarm buzzer —...
Page 88: Door-Open Lock
OPERATION EXPLANATION OF COMPONENTS DOOR-OPEN LOCK (MACHINES EQUIPPED WITH CAB) Use this when you want to keep the door held open. Push the door against door catch (1). The door will be held by the door catch. To release the door, move lever (2) inside the cab to the front of the cab.
Page 89: Hot And Cool Box
OPERATION EXPLANATION OF COMPONENTS HOT AND COOL BOX (MACHINES EQUIPPED WITH CAB) This is at the top of the front panel. It can be used to warm or cool three canned drinks. This is interconnected with the air conditioner: During heating, it warms up the drinks;...
Page 90: Tool Box
OPERATION EXPLANATION OF COMPONENTS TOOL BOX This is inside the right engine side cover. It is used for storing tools. 3-40...
Page 91: Using Car Radio
OPERATION EXPLANATION OF COMPONENTS USING CAR RADIO (MACHINES EQUIPPED WITH CAB, CAR RADIO) EXPLANATION OF PARTS Power switch/volume control knob (push ON/VOL) (5) Preset button (1, 2, 3, 4, 5, 6) Tone control knob (TONE) Time adjustment button (T, ADJ) Display button (DISP) Time reset button (RESET) Tuning/hour, min adjustment button (TUNE)
Page 92 OPERATION EXPLANATION OF COMPONENTS TONE CONTROL KNOB (TONE) Turn this knob (2) clockwise from the center position to empha- size the high sounds, and counterclockwise to emphasize the low sounds. DISPLAY BUTTON (DISP) If the display button (3) is pressed when the radio is being used, the frequency of the station being listened to is displayed for 5 seconds.
Page 93 OPERATION EXPLANATION OF COMPONENTS TIME ADJUSTMENT BUTTON (T, ADJ) Press this button (6) to adjust the time. TIME RESET BUTTON (RESET) Press this button (7) to reset to the exact hour. DISPLAY This display (8) displays the frequency, time, and preset sym- bols.
Page 94 OPERATION EXPLANATION OF COMPONENTS METHOD OF USE Method of setting preset buttons Press power switch (1). The frequency is displayed in display area (8). Use selector button (4) ( ) to adjust to the desired frequency. Choose a preset button to use for this station, and keep it pressed for at least 2 seconds to program the button to that frequency.
Page 95 OPERATION EXPLANATION OF COMPONENTS Adjusting time Keep T.ADJ button (6) pressed, and press H button (A). The hour display will change, so when it reaches the cor- rect hour, release the button. Keep T.ADJ button (6) pressed and press M button (B). The minute display will change, so when it reaches the correct time, release the button.
Page 96: Am/Fm Radio
OPERATION EXPLANATION OF COMPONENTS AM/FM RADIO 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 Tape eject button (14) Band selector button...
Page 97 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 98 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 99 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 the radio plays. CASSETTE DOOR Set the cassette with the exposed portion of the tape on the right side and insert it in cassette door (8).
Page 100 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. MANUAL TUNING BUTTONS When the button of button (12) is pressed, the frequency...
Page 101 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS To listen to a preset station, use band selector button (1) to select AM, FM1, or FM2, then press the preset switch number to listen to the desired station. It is possible to preset six AM stations and 12 FM stations (FM1:6, FM2:6).
Page 102 OPERATION EXPLANATION OF COMPONENTS LISTENING TO RADIO Turn the starting switch ON, then turn power switch (1) Set band selector button (2) to AM or FM. Select the station with the preset buttons or manual tun- ing button (3). Adjust the volume, balance, and tone as desired. When turning the radio OFF, turn power switch (1) to the left until there is a click.
Page 103 OPERATION EXPLANATION OF COMPONENTS REVERSING TAPE W h e n l i s t e n i n g t o t h e t a p e , p r e s s b o t h FA S T F O R - WARD,REWIND buttons (A) and (B) at the same time lightly.
Page 104: Handling Air Conditioner
OPERATION EXPLANATION OF COMPONENTS HANDLING AIR CONDITIONER (MACHINES EQUIPPED WITH CAB) COOLING OPERATION When the cooling operation is carried out, the inside of the cab is cooled, and at the same time the drinks inside the hot and cool box can be cooled. Cooling (RECIRC) When the control switch and lever are operated as shown in the diagram, a cool breeze is sent out.
Page 105 OPERATION EXPLANATION OF COMPONENTS HEATING OPERATION When the heating operation is carried out, the inside of the cab is heated, and at the same time the drinks inside the hot and cool box can be heated. Heating (RECIRC) When the control switch and lever are operated as shown in the diagram, warm air is sent out.
Page 106 OPERATION EXPLANATION OF COMPONENTS PRECAUTIONS WHEN USING AIR CONDITIONER Carry out ventilation from time to time when using the cooler. If you smoke when the cooler is on, the smoke may start to hurt your eyes, so turn the lever to FRESH to remove the smoke while continuing the cooling.
Page 107 OPERATION EXPLANATION OF COMPONENTS CLEANING AIR FILTER If the air filter for the FRESH or RECIRC air intake becomes clogged, the cooling or heating capacity will drop. To prevent this, clean the air filter with compressed air once a week. For details of the cleaning method, see "CLEAN AIR CONDITIONER AIR FILTER (PAGE 4-36)".
Page 108: Handling Heater
OPERATION EXPLANATION OF COMPONENTS HANDLING HEATER (MACHINES EQUIPPED WITH CAB) METHOD OF OPERATION To heat quickly Set the switches to the position shown in the diagram on the right to carry out heating quickly. Set FRESH/RECIRC selector lever (1) and temperature control lever (3) to the position in the diagram on the right.
Page 109: Handling Accumulator
Do not weld any boss to the accumulator. When disposing of the accumulator, it is necessary to release the gas from the accumulator, so please contact your Komatsu distributor. The accumulator is a device to store the pressure in the control circuit, and when it is installed, the control circuit can be oper- ated for a short time even after the engine is stopped.
Page 110: Operation
Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and be sure to repair any abnormalities, or please contact your Komatsu distributor. When inspecting,if the machine is at an angle,move it to a horizontal place to carry out the check.
Page 111 (1) second. REMARK If the lamps do not light up,there may be a failure or disconnec- tion in the monitor, so please contact your Komatsu distributor. NOTICE When carrying out the checks before starting, do not relay only on the monitor.
Page 112 OPERATION OPERATION CHECK COOLANT LEVEL, ADD WATER WARNING Normally, do not open the radiator cap. When checking the cooling water level, check the sub-tank when the engine is cold. Do not remove the cap when the radiator water is hot. Boiling water may spurt out. After the water temperature goes down, turn the cap slowly to release the pressure, then remove it.
Page 113 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If you spill fuel, thoroughly clean up any spillage. Turn the engine starting switch to the ON position and check the fuel level with fuel level gauge (G) on the mon- itor panel.
Page 114 OPERATION OPERATION DRAIN WATER,SEDIMENT FROM FUEL TANK Loosen drain valve (1) at the bottom of the fuel tank and drain the sediment and water accumulated at the bottom of the tank together with the fuel. 3-64...
Page 115 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. 1.Open the engine side cover on the left side of the chas- sis.
Page 116 OPERATION OPERATION CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL Remove dipstick (G), and wipe the oil off with a loth. Insert dipstick (G) fully in the dipstick holder, then take it out again. The oil level should be between the H and L marks on dipstick (G).
Page 117 OPERATION OPERATION CHECK BRAKE PEDAL TRAVEL Drive the machine, depress the brake pedal, and check that the machine stops. CHECK DAMPER CASE OIL LEVEL, ADD OIL Open engine side cover (1) on the left side of the machine. Remove dipstick (G), and wipe the oil off with a loth. Insert dipstick (G) fully into the dipstick holder, then pull it out again.
Page 118 OPERATION OPERATION CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING When removing the oil filler cap, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap.
Page 119 If the fuses are frequently blown or if there are traces of short circuits on the electrical wiring, locate the cause immediately and carry out repairs, or contact your Komatsu distributor for repairs. If flammable materials (dead leaves, twigs, dry grass, etc.) accumulate around the battery, they will cause fire, so always remove such material immediately.
Page 120 ON position and check that the front lamp and rear lamp light up. If the lamps do not light up, there is probably a broken bulb or disconnection in the wiring, so contact your Komatsu distributor for repairs. 3-70...
Page 121 OPERATION OPERATION CHECK HORN SOUND Turn the key of starting switch (1) to the ON position. Press the horn switch and check that the horn sounds. 3-71...
Page 122 OPERATION OPERATION CHECK BACKUP ALARM SOUND Turn the key of starting switch (1) to the ON position. Set the joystick to the REVERSE position. The buzzer must sound immediately. The buzzer will continue to sound until the joystick is moved to the NEUTRAL or FORWARD position.
Page 123 OPERATION OPERATION ADJUSTING BEFORE STARTING OPERATION WARNING Adjust the seat position at the beginning of each shift or when operators change. Adjust the seat so that the brake pedal can be depressed all the way with the operator's back against the backrest.
Page 124 OPERATION OPERATION ADJUSTING MIRROR (MACHINES EQUIPPED WITH CAB) Loosen screw (1) which is installed on the mirror, and adjust the mirror to the best position to see the mirror from the opera- tor's seat. Especially for seeing behind the machine, adjust in such a way that you can easily see persons at the rear L.H and R.H cor- ners.
Page 125 OPERATION OPERATION USING SEAT BELT Always install a seat belt on machines equipped with ROPS. WARNING Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting belt of the belt. If the belt is worn or damaged, replace it. Replace the seat belt every three years, even if their outside is free from abnormality.
Page 126 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. Loosen knob (1) on the left and right sides of the opera- tor's seat.
Page 127 OPERATION OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check that the safety lock lever is securely at 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 128 OPERATION OPERATION Check that joystick (2) is at the 1st position. Check that the blade is lowered to the ground and that blade control lever (3) is at the HOLD position. Check that the ripper is lowered to the ground. Check that the safety lever (4) is locked.
Page 129: Starting Engine
OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Exhaust gas is toxic. When starting the engine in con- fined spaces, be particularly careful to ensure good ventilation.
Page 130 OPERATION OPERATION When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position. Even if the engine has started, if the engine oil pressure monitor lamp is lighted up, do not touch the work equip- ment control levers or brake pedal.
Page 131 OPERATION OPERATION STARTING IN COLD WEATHER WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Never use starting aid fluids as they may cause explo- sions. NOTICE Do not crank the starting motor continuously for more than 20 seconds.
Page 132 OPERATION OPERATION Insert the key into the starting switch (2) and turn the key to the ON position. When the key is turned to the ON position, preheat- ing is automatically carried out according to the ambient temperature (engine water temperature). The preheating pilot lamp (3) lights up during the preheating operation.
Page 133 OPERATION OPERATION While preheating is being carried out, the preheating pilot lamp (3) lights up to show that preheating is being carried out. After it lights up for 36 seconds, it flashes for 16 seconds and goes out. When it goes out, complete the preheating immediately. If the engine does not start with the above operation, wait for about 2 minutes, and repeat steps from Step 2.
Page 134 OPERATION OPERATION In cold weather, the turbo protect function is actuated, so the engine speed is maintained below 1,000 rpm for several seconds. After that, it changes to the speed specified by the set position of fuel control dial. 3-84...
Page 135: After Starting Engine
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 136: Warming-Up Operation
OPERATION OPERATION WARMING-UP OPERATION After starting the engine, do not immediately start operations. First, carry out the following operations and checks. NOTICE Avoid abrupt acceleration until warm-up run is completed. Do not run the engine at low idling or high idling for more than 20 minutes.
Page 137 OPERATION OPERATION Turn fuel control dial (1) to the center position between LOW IDLING (MIN) and HIGH IDLING (MAX) and run the engine at medium speed for about 5 minutes with no load. After warm-up run is completed, check gauges and cau- tion lamps for proper operation.
Page 138 OPERATION OPERATION IN COLD AREAS After starting the engine, do not immediately start operations. First, carry out the following operations and checks. NOTICE Avoid abrupt acceleration until warm-up run is completed. Do not run the engine at low idling or high idling for more than 20 minutes.
Page 139 OPERATION OPERATION Operate blade control lever (9) to the RAISE position, then keep the blade raised to the maximum height and continue to relieve the circuit for 10 minutes. Finally, operate blade control lever (9) and ripper control lever (10) to operate all the blade and ripper cylinders several times.
Page 140: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradu- ally, then stop it.
Page 141: Check After Stopping Engine
OPERATION OPERATION CHECK AFTER STOPPING ENGINE Walk around the machine and check the work equipment, machine exterior, and undercarriage, and check also for leakage of oil or water. If any abnormalities are found, repair them. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard. Remove any mud affixed to the undercarriage.
Page 142: Machine Operation
OPERATION OPERATION MACHINE OPERATION MOVING MACHINE OFF WARNING When moving machine, check that the area around the machine is safe, and sound the horn before mov- ing. Clear all personnel from the machine and the area. Clear all obstacles from the path of the machine. Use extreme care when reversing the machine.
Page 143 OPERATION OPERATION Set joystick (3) to the desired position. Set safety lever (6) for blade control lever (4) and ripper control lever (5) to the FREE position. Operate blade control lever (4) and ripper control lever (5) to the RAISE position, raise the blade 40 - 50 cm (15.8 - 19.7 in) from the ground, and raise the ripper to the maximum height.
Page 144 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 nec- essary to park the machine on a slope, place the park- ing lever in the LOCK position and insert blocks underneath the track shoes.
Page 145 OPERATION OPERATION SHIFTING GEAR It is possible to change the speed range when traveling, so there is no need to stop the machine when shifting gear. Move joystick (1) to the desired gear position to shift gears. Gear shifting Rotate the joystick 30º to carry out gear shifting operation. Position (A): 1st Position (B): 2nd Position (C): 3rd...
Page 146 OPERATION OPERATION REMARK When gear shifting operation is carried out, the display panel will display the used speed range. NEUTRAL 1st: N1 is displayed on the display panel FORWARD 2nd: F2 is displayed on the display panel REVERSE 3rd: R3 is displayed on the display panel SHIFTING BETWEEN FORWARD AND REVERSE CAUTION There is no need to stop the machine even when switch-...
Page 147 OPERATION OPERATION Return joystick (1) to the neutral position, reduce the speed, then depress brake pedal (3) and stop the machine. After depressing decelerator pedal (2), move joystick (1) to the desired position. Release decelerator pedal (2) to raise the engine speed. 3-97...
Page 148: 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 land. Never make a pivot turn at high speed. NORMAL TURNING WARNING The feeling of the operation if the operator carries out a...
Page 149 OPERATION OPERATION Turnig to left while traveling forward NOTICE If the lever is operated partially to the forward or reverse position and then is operated in the direction of turn, the machine may carry out a counterrotation turn,so operate the lever fully to the forward or reverse position. If the joystick (1) is pushed forward and moved partially to the left (L), the machine will start to turn gradually.
Page 150 OPERATION OPERATION TURNING WHILE DESCENDING A SLOPE With machines that can carry out counterrotation turns, on steep downhill slopes where the machine may travel under its own weight, or on downhill slopes where it is being pushed by a towed machine, the machine will not steer in the opposite direction, so do as follows.
Page 151: Precautions For Operation
OPERATION OPERATION PRECAUTIONS FOR OPERATION PERMISSIBLE WATER DEPTH When operating in water, always keep center line (1) of the idler above the surface of the water. Also, be careful that the engine cooling fan will not come in contact with water. The fan can be damaged. PAY ATTENTION TO GAUGES When the red range lights up on the transmission oil temperature gauge while operating, reduce load and wait for lowering of temperature.
Page 152 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 153: 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 nec- essary to park the machine on a slope, place the park- ing lever in the LOCK position and insert blocks underneath the track shoes.
Page 154 OPERATION OPERATION Place joystick (2) in NEUTRAL position and set the speed range to 1st. Operate parking lever (4) to lock the brakes. Operate blade control lever (5) and ripper control lever (6) to the LOWER position, and lower the blade and rip- per to the ground.
Page 155: Check After Finishing Work
OPERATION OPERATION CHECK AFTER FINISHING WORK Use the meters and caution lamps to check the engine water temperature, engine oil pressure, fuel level, power train oil temperature gauge, charge lamp, HSS charge oil pressure and HSS oil temperature. LOCKING To prevent vandalism, there are locks at the following places. Places that can be locked with the starting switch key.
Page 156: Ripper Operation
OPERATION OPERATION RIPPER OPERATION EFFECTIVE METHOD OF USE The optimum digging angle for the shank is when the shank is perpendicular to the ground (ripping angle:45º - 50º). In comparatively soft rock (seismic velocity:1200 m/s or below), it is also possible to carry out ripping with the shank tilted to the rear (max.ripping angle).
Page 157 OPERATION OPERATION OPERATING ON SLOPES When using the variable ripper, adjust the length of the tilt cylin- der to select dimension L. METHOD OF OPERATING PIN PULLER This is used only on machines equipped with a giant ripper. Stop the machine in a safe place and lower the shank to the ground.
Page 158: 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 159 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 blade. FELLING TREES, REMOVING STUMPS NOTICE Do not up root trees or stumps by angling or tilting the blade.
Page 160: Adjusting Posture Of Work Equipment
OPERATION OPERATION ADJUSTING POSTURE OF WORK EQUIPMENT METHOD OF ANGLING BLADE (ANGLEDOZER ONLY) Angle the blade when it is needed to dump the soil on one side. WARNING When adjusting the amount of angling, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the safety lever.
Page 161 OPERATION OPERATION REMARK When assembling an angle dozer to the C-frame, adjust the clearance of the center joint by adjusting the length of arm (2) and brace (3) so that dimension S of center joint (4) is 20 mm (0.8 in). ADJUSTING TILT AMOUNT (ANGLEDOZER, POWER TILTDOZER, POWER TILT POWER PITCHDOZER) WARNING...
Page 162 OPERATION OPERATION Raise the blade 300 - 400 mm (11.8 - 15.8 in)above the ground, then put blocks under the frame so that the blade does not come down. Loosen set bolt (1) of the brace, insert a suitable bar into hole (2) of the brace, and turn it.
Page 163 OPERATION OPERATION If a greater tilt amount is needed,use adjustment bar (2) installed to left brace (1) to rotate brace (1) and change the brace length. It is possible to tilt to a maximum of 1000 mm (39.4 in). REMARK When adjusting the tilt in Steps 1 and 2, carry out the operation with the blade raised from the ground.
Page 164 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 nor- mal use, use the bottom hole, and when particularly deep digging is needed, use the top hole. To change the digging depth, do as follows.
Page 165 OPERATION OPERATION If the wear exceeds the wear limit in the table below, replace the worn parts. Unit:mm (in) Basic dimension Wear limit (1) Point 335 (13.2) 225 (10.0) (2) Protector 115 (4.5) 90 (3.5) ADJUST ANGLE OF BLADE EDGE (ANGLEDOZER, POWER TILTDOZER, POWER TILT POWER PITCHDOZER) WARNING It is dangerous if the work equipment moves by mistake when adjusting angle of the blade edge.
Page 166 OPERATION OPERATION Power tiltdozer Turn the brace with bar handle (1) to change the distance ( ) between the joints to change the cutting angle (θ) as follows. INCREASE distance ( ) to INCREASE angle (θ) DECREASE distance ( ) to DECREASE angle (θ). The standard for the cutting angle (θ) is 52º.
Page 167: Tips For Longer Undercarriage Life
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. Do not allow shoe slipping to occur during operation. If shoe slipping occurs, reduce load to the blade until slip- ping stops.
Page 168 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 repair limits and reversing limits.
Page 169 OPERATION OPERATION MEASURING OUTSIDE DIAMETER OF TRACK ROLLER Measure height (size C) of link tread as shown. Stop machine at position where link tread, whose size C has been measured, completely contacts roller tread. Then measure size B. Calculate outside diameter of tread (size A): A = (B - C) x 2 Standard size (A): 250 mm (9.9 in) Repair limits:...
Page 170: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. LOADING, UNLOADING WORK WARNING Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely loaded and unloaded.
Page 171: Method Of Lifting Machine
This description of the method for lifting the chassis applies to standard specification machines. Depending on the attachments and options installed, the method of lifting will differ. In such cases, please contact your Komatsu distributor for advice. For details of the weight, see "SPECIFICATIONS (PAGE 5-2)". 3-121...
Page 172: Precautions For Transportation
OPERATION TRANSPORTATION PRECAUTIONS FOR TRANSPORTATION WARNING Determine the route for transporting the machine by taking into account the width, height and weight of the machine. Obey all state and local laws governing the weight, width and length of a load. Observe all regulations governing wide loads.
Page 173: Removal Of Cab
OPERATION TRANSPORTATION REMOVAL OF CAB (MACHINES EQUIPPED WITH CAB) If it is necessary to remove the cab for transportation, discon- nect the washer hoses, cab wiring, and washer motor wiring before removing the cab. Push the grommet portion from the hole in the machine cover towards the cab, then remove.
Page 174 OPERATION TRANSPORTATION REMARK When installing the cab, check the colors of the washer tank and window washer hoses, and be sure to connect correctly. When installing the cab, please contact your Komatsu dis- tributor for installation. 3-124...
Page 175: Cold Weather Operation
Antifreeze is toxic. Be extremely careful when handling it. When replacing coolant containing anti- freeze or when handling coolant when repairing the radiator, contact your Komatsu distributor or ask your local antifreeze dealer. Be careful not to let the water flow into drainage ditches or spray on to the ground surface.
Page 176 OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas, so 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 large amount of water, and consult a doctor.
Page 177: After Daily Work Completion
OPERATION COLD WEATHER OPERATION AFTER DAILY WORK COMPLETION WARNING Performing idle-running of the tracks is dangerous, so stay well away from the tracks. After completion of operations, fill the fuel tank to prevent the formation of water caused by conden- sation of moisture in the empty space in the tank when the temperature goes down.
Page 178: Long Term Storage
NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. When using the machine after long-term storage, do as follows before using it. Wipe off all the grease coating the hydraulic cylinder rods.
Page 179: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL WARNING When air bleed plug (2) at the top of the fuel filter head or supply pump air breather (4) are removed, the system is still under pressure, so fuel may spurt out. Loosen these parts slowly before opening them. When starting after running out of fuel, fill the filter cartridge with fuel and bleed the air from the fuel system before starting.
Page 180: Method Of Towing Machine
OPERATION TROUBLESHOOTING Push the knob of priming pump (3) in and tighten it. If the air is not bled properly, return to Step 3 and bleed the air again. For normal starting operations, turn the key in the starting switch to the START position to start the engine. METHOD OF TOWING MACHINE WARNING When towing the machine, use a wire rope that has ample strength for the weight of the machine...
Page 181: Discharged Battery
OPERATION TROUBLESHOOTING DISCHARGED BATTERY WARNING It is dangerous to charge the battery while it is still mounted on the machine. Always remove the battery before charging it. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position.
Page 182 OPERATION TROUBLESHOOTING REMOVAL AND INSTALLATION OF BATTERY NOTICE After fixing the battery in position, check that it does not move. If it moves, install it again. When removing, remove from the ground side first (normally the negative (-) terminal). Be careful not to touch between the (+) terminal and the machine with any tool. Letting a tool touch is danger- ous as it causes sparks.
Page 183 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLES When starting the engine with a booster cable, do as follows: REMOVAL, INSTALLATION OF BATTERY CABLE Open battery cover (1) and (2). Before removing the battery, remove the ground cable (normally connected to the negative (-) terminal). If any tool touches between the positive terminal and the chas- sis, there is danger of sparks being generated.
Page 184 OPERATION TROUBLESHOOTING Make sure that the cables and clips are firmly connected. Check that the safety lock levers and parking brake levers of both machine are in the LOCK position. Check that each lever is in the NEUTRAL position. BOOSTER CABLE CONNECTION Keep the starting switch of the nornal machine and problem machine both at the OFF position.
Page 185: Other Trouble
OPERATION TROUBLESHOOTING OTHER TROUBLE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. ELECTRICAL SYSTEM Problem Main causes Remedy...
Page 186 OPERATION TROUBLESHOOTING Problem Main causes Remedy Air conditioner does not work prop- Blown fuse ( Check, repair) erly Insufficient battery charge Charge Defective air conditioner switch ( Replace air conditioner switch) Defective blower switch ( Replace blower switch) Defective compressor ( Replace) HSS charge pressure caution lamp Defective caution lamp...
Page 187 Abnormality in sensor for service meter portion it is still possible to carry out displaying engine speed on operations. Please contact monitor panel your Komatsu distributor Abnormality in buzzer can- immediately for repairs. cel switch Abnormality in water tem- Abnormality code and service...
Page 188 OPERATION TROUBLESHOOTING CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy When brake pedal is depressed,...
Page 189 OPERATION TROUBLESHOOTING Problem Main causes Remedy Torque converter overheats Lack of oil in power train case Add oil to specified level. (Red range of power train oil tem- See CHECK BEFORE START- perature gauge lights up) Transmission oil pressure does See "Transmission oil pressure not rise does not rise"...
Page 190 OPERATION TROUBLESHOOTING ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure caution lamp...
Page 191 Damage inside muffler ( Replace muffler) Excessive valve clearance ( Adjust valve clearance) Monitor displays error code Please contact your Komatsu distributor Alarm buzzer sounds Engine horsepower lowered sud- denly (engine is running in deration mode) 3-141...
Page 192 MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 193: Guide To Maintenance
KOMATSU GENUINE REPLACEMENTPARTS: 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 windshield washer fluid, and be sure not to let any dirt get into it.
Page 194 MAINTENANCE GUIDE TO MAINTENANCE DO NOT DROP THINGS INSIDE MACHINE: When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop nuts, bolts, or tools inside the machine. If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will lead to failure.
Page 195 MAINTENANCE GUIDE TO MAINTENANCE LOOKING THE INSPECTION COVERS: When carrying out maintenance with the inspection cover open, lock it in position securely with a lock bar. If inspection or maintenance is carried out with the inspection cover open and not locked in position, there is a haz- ard that it may be suddenly blown shut by the wind and cause injury to the worker.
Page 196: Outline Of Service
We recommend you to 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 The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Page 197 When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
Page 198 Make sure that the oil is well mixed before sampling. Carry out sampling regularly at fixed intervals. 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.
Page 199: Electric System Maintenance
Service relating to the electric system is check of fan belt tension, check of damage or wear in the fan belt and check of battery fluid level. Never install any electric components other than there specified by Komatsu. External electrical interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your Komatsu distributor.
Page 200: Wear Parts
The wear parts should be changed correctly in order to use the machine economically. When changing parts,use Komatsu genuine parts of excellent quality. When ordering parts, please check the part number in the parts book.
Page 201 MAINTENANCE WEAR PARTS Weight Replacement Item Part No. Part Name Q'ty (kg) frequency 175-78-31230 Point Multi 195-78-21320 Protector — 09244-02508 (Pin) — Ripper 175-78-31230 Point Giant 195-78-21320 Protector — 09244-02508 (Pin) — NOTICE When handling parts that weigh more than 25 kg (55 lb), remember that they are heavy objects, and take the necessary care.
Page 202: 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 NOTICE Use only diesel fuel. The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel consumption and good exhaust gas characteristics.
Page 203 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil than matches the temparature in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydrauric work equipment applications.
Page 204 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 205 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 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.) FINA potonic N...
Page 206: Standard Tightening Torques For Bolts And Nuts
The tightening torque is determined by the width across the flats of the nut and bolt. 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 207: Periodic Replacement Of Safety Critical Parts
These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. With these parts, the material changes as time passes, or they easily wear out or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition.
Page 208: Safety Critical Parts
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q'ty Replacement interval Fuel tank - hand priming pump Engine overflow nipple - joint (bottom of fuel tank) Engine overflow nipple - joint (bottom of fuel tank) Joint (bottom of fuel tank) - fuel tank (overflow) Joint (bottom of fuel tank) - fuel tank (spill) Hand priming pump - supply pump...
Page 209 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q'ty Replacement interval HSS pump - cooler bypass valve Cooler bypass valve - oil cooler Cooler bypass valve - oil cooler Oil cooler - cooler bypass valve Oil cooler - cooler bypass valve Cooler bypass valve - hydraulic tank Work equipment hydraulic pump - CLSS valve...
Page 210: Maintenance Schedure Chart
MAINTENANCE MAINTENANCE SCHEDURE CHART MAINTENANCE SCHEDURE CHART MAINTENANCE SCHEDURE CHART INITIAL 250 HOURS MAINTENANCE REPLACE POWER TRAIN OIL FILTER ELEMENT................... 4-52 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS................4-57 CHANGE OIL IN FINAL DRIVE CASE ....................... 4-59 REPLACE CHARGE FILTER ELEMENT......................4-63 CHANGE OIL IN HYDRAULIC TANK,REPLACE HYDRAULIC OIL FILTER ELEMENT ........
Page 211 MAINTENANCE MAINTENANCE SCHEDURE CHART EVERY 500 HOURS SERVICE REPLACE FUEL FILTER CARTRIDGE......................4-51 REPLACE POWER TRAIN OIL FILTER ELEMENT ................... 4-52 REPLACE HYDRAULIC TANK BREATHER ELEMENT ..................4-53 CHECK AND REPLACE FAN BELT ........................4-54 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........4-55 EVERY 1000 HOURS SERVICE CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS ................
Page 212: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Carry out the following maintenance only after the first 250 hours of operation on new machines. REPLACE POWER TRAIN OIL FILTER ELEMENT CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAV- ENGING PUMP STRAINER) CHANGE OIL IN FINAL DRIVE CASE REPLACE CHARGE FILTER ELEMENT...
Page 213: When Required
MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CLEAN INSIDE OF COOLING SYSTEM WARNING Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine to cool before draining water. Never be under the machine with the engine running. To avoid serious injury, always stop the engine before being under the machine to open the drain valve.
Page 214 If it gets in your eyes, flush your eyes with large quantity of fresh water and see a doctor at once. Use city water for the cooling water. 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 215 MAINTENANCE SERVICE PROCEDURE 10. When the water reaches near the water filler port, open drain valve (4), run the engine at low idling, and carry out the flushing operation until clean water comes out. When flushing, adjust the amount of water added and drained to ensure that the radiator is always full of water.
Page 216: Check, Clean And Replace Air Cleaner Element
MAINTENANCE SERVICE PROCEDURE CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING Never clean or replace the air cleaner element with the engine running. When using coompressed air to clean the element, wear safety glasses or goggles to protect the eyes. CHECK When the yellow display panel indicating the pressure of dust indicator (1) goes over the red line, clean the air cleaner ele-...
Page 217 MAINTENANCE SERVICE PROCEDURE Direct dry compressed air (less then 700 kPa (7 kg/cm 100 psi)) to the element from inside along its folds,then direct it from outside along its folds and again from inside. Remove one seal from the outer element. The num- ber of times the outer element has been cleaned can be seen by the number of removed seals.
Page 218: Check Electrical Intake Air Heater
MAINTENANCE SERVICE PROCEDURE 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. CHECK TRACK TENSION The wear of pins and bushings on the undercarriage will vary with the working conditions and soil properties. It is thus necessary to continually inspect the track tension so as to maintain the standard tension.
Page 219 WARNING 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. Remove both bolts (3), then remove cover (2).
Page 220: Check And Tighten Track Shoe Bolts
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 for tightening (shoe bolt) First tighten to a tightening torque of 588 ± 58.8 N•m (60 ±...
Page 221: Reverse And Replace The End Bits And Cutting Edges
MAINTENANCE SERVICE PROCEDURE REVERSE AND REPLACE THE END BITS AND CUTTING EDGES WARNING It is dangerous if the blade moves by mistake when the cutting edges and end bits are being reversed or replaced. Set the blade in a stable condition, then stop the engine and lock the blade control lever securely with the safety lever.
Page 222: Clean, Check Radiator Fins
MAINTENANCE SERVICE PROCEDURE Reverse or replace the cutting edge and the end bit when worn out. Nut tightening torque: Semi-U blade: 1330 to 1660 N•m (136 to 169 kgf•m, 983.7 to 1,222.4 lbft) Angledozer: 738 to 999 N•m (75.3 to 101.9 kgf•m, 544.6 to 737 lbft) If bolt (2) and nut (1) are damaged, replace them with new ones at the same time.
Page 223: Replace Air Conditioner Belt
MAINTENANCE SERVICE PROCEDURE REPLACE AIR CONDITIONER BELT Loosen 4 bolts (1) and jack bolt (2), then move compres- sor (3) to the side. Replace the V-belt. When adjusting the V-belt, do not push the compres- sor directly with a bar. Use jack bolt (2). Tighten jack bolt (2) and bolts (1), and apply tension to the V-belt.
Page 224: Clean, Check Hydraulic Cooler Fins
MAINTENANCE SERVICE PROCEDURE CLEAN, CHECK HYDRAULIC COOLER FINS If the hydraulic cooler fins are clogged or there is dirt caught in the fins, clean and check the fins. Open the radiator mask. For details on how to open the radiator mask, see "CLEAN, CHECK RADIATOR FINS (PAGE 4-31)".
Page 225: Clean, Check Air Conditioner Condenser Fins
MAINTENANCE SERVICE PROCEDURE CLEAN, CHECK AIR CONDITIONER CONDENSER FINS If the air conditioner condenser fins are clogged, clean and check the fins. Remove 3 mounting bolts (1) of the upper cover, then remove upper cover (2). Use compressed air to blow off the mud, dirt, or leaves clogging the fins.
Page 226: Check Undercarriage Oil
If oil oozes out, the oil level has not gone down, so tighten the bolt. If no oil comes out even when seal bolt (1) is removed, the oil level is low, so please contact your Komatsu dis- tributor for repair. REMARK On the idler, seal bolt (1) cannot be seen unless outside cover is removed.
Page 227: Clean Air Conditioner Air Filter
MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (MACHINES EQUIPPED WITH CAB) If the air conditioner air filter is clogged or there is dirt or dust in it, clean the filter. Open inspection cover (1), open cover (2), then remove FRESH filter (3).
Page 228: Check, Adjust Air Conditioner
MAINTENANCE SERVICE PROCEDURE CHECK, ADJUST AIR CONDITIONER (MACHINES EQUIPPED WITH CAB) CHECKING TENSION OF COMPRESSOR BELT If the belt is loose, it will slip and the cooling effect will be reduced. From time to time, press a point midway between the drive pulley and compressor pulley with your finger (approx.6 kg (13 lb)) and check that the tension is 10 mm (0.39 in).
Page 229: Grease Door Hinge
MAINTENANCE SERVICE PROCEDURE GREASE DOOR HINGE (MACHINES EQUIPPED WITH CAB) 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 LOCK STRIKER (MACHINES EQUIPPED WITH CAB) If the wear of the doors lock striker exceeds 0.5 mm (0.02 in),...
Page 230: Check Door Latch
MAINTENANCE SERVICE PROCEDURE CHECK DOOR LATCH WARNING If the control lever is touched by accident during check- ing, the machine moves off suddenly, and this may lead to serious injury or death. Before checking door latch, stop the engine and set the parking lever securely to the LOCK position.
Page 231: Replace Door Damper
MAINTENANCE SERVICE PROCEDURE REPLACE DOOR DAMPER (MACHINES EQUIPPED WITH CAB) If the depth of the door damper rubber groove is less than 2 mm (0.08 in), replace the damper. There are two dampers each at the top and bottom on the left and right doors.
Page 232: Replace Wiper Blade
MAINTENANCE SERVICE PROCEDURE REPLACE WIPER BLADE (MACHINES EQUIPPED WITH CAB) If the blade is damaged, it will not wipe the window clean, so replace the blade. Method of replacement Front, rear wiper Remove screw (1),then remove the blade. Install a new blade, then tighten screw (1) securely. Door wiper It is hooked at portion (A), so move the blade in the direc- tion of the arrow to remove it.
Page 233: Procedure For Bleeding Air In Hydraulic System
MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM See "STARTING ENGINE (PAGE 3-79)". Since the engine must be started and the blade must be operated, see OPERATION. NOTICE If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air inside the cylinder may cause damage to the piston packing.
Page 234: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-61)" in the OPERATION section. Check coolant level, add water Checking with machine monitor (Monitor panel specification) Check fuel level, add fuel Drain water, sediment from fuel tank Check oil level in engine oil pan, add oil Check oil level in power train case, add oil Check brake pedal travel...
Page 235: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE LUBRICATING Lower the work equipment to the ground, then stop the engine. Using a grease pump,pump in grease through the grease fittings shown by arrows. After greasing, wipe off any old grease that was pushed out. Grease fan pulley (1 place) Front of engine side cover (left) Grease equalizer bar side pin (4 places)
Page 236 MAINTENANCE SERVICE PROCEDURE Grease equalizer bar center pin (1 place) Open the engine side cover at the left side of the machine, then remove 2 bolts (1). Pull hinged cover (2) out and open it. Add grease through the grease fitting marked by the arrow.
Page 237 MAINTENANCE SERVICE PROCEDURE Angledozer Lift cylinder support yoke (4 places) Lift cylinder support shaft (2 places) Tilt brace thread (2 places) Ripper Tilt cylinder bottom pin (2 places) Lift cylinder bottom pin (2 places) Tilt cylinder rod end pin (2 places) Lift cylinder rod end pin (2 places) Arm pin (front) (2 places) Arm pin (rear) (2 places)
Page 238: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. Stop the machine so that drain plug (1) is directly at the bottom.
Page 239 Should distilled water have been added above the bottom of the sleeve, lower the level to the bottom using a pipette. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water, or consult the Komatsu distributor or the battery manufacturer. 4-48...
Page 240: Check, Adjust Alternator Drive Belt Tension
V-groove. When an abnormality is detected, ask your Komatsu distributor to replace the pulley. If the V-belt is elongated and there is no more allowance for adjustment,or if the belt is cracked or cut, replace the belt.
Page 241: 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. NOTICE Do not place the joystick in the 1st speed position. Otherwise, it will cause damage to the machine.
Page 242: Every 500 Hours Service
The common rail fuel injection system used on this machine consists of more precise parts than the conven- tional 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 243: Replace Power Train Oil Filter Element
Tighten air bleed plug (2), push in the knob of priming pump (3), then tighten it. Use a genuine Komatsu part for the fuel filter cartridge. After replacing the filter cartridge, run the engine, and check for any leakage of oil from the filter seal surface.
Page 244: Replace Hydraulic Tank Breather Element
MAINTENANCE SERVICE PROCEDURE REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING Replace the element when the oil is cold. When removing breather cap (1), turn it slowly to release the internal pressure before removing it. Remove breather cap (1) at the top of the hydraulic tank. Replace element (2) inside the cap.
Page 245: Check And Replace Fan Belt
MAINTENANCE SERVICE PROCEDURE CHECK AND REPLACE FAN BELT Check the V-belt and when the following conditions exist, replace the V-belt. When the V-belt makes contact with the bottom of the groove in each pulley. When the V-belt is worn, and its surface is lower than the outer diameter of the pulley.
Page 246: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. Install drain plug (P) and drain valve (2) . Tightening torque Drain plug (P): 68.6 ± 9.8 N•m (7 ±...
Page 247 MAINTENANCE SERVICE PROCEDURE Clean the filter holder, fill the new filter cartridge with engine oil, coat the packing surface and thread with engine oil (or coat it thinly with grease), then install the fil- ter cartridge. REMARK Confirm that no remnants of old packing still adhere to the filter holder as this may result in oil leakage.
Page 248: 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 249 MAINTENANCE SERVICE PROCEDURE Loosen mounting bolt (10) of the scavenging pump strainer, then remove cover (11). Remove strainer (12). Remove any dirt stuck to strainer (12), then wash it in clean diesel oil or flushing oil. Wash the removed parts and the inside of the case at the same time.
Page 250: Change Oil In Final Drive Case
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. Prepare the following. Refill capacity: each 58 (15.31 US gal,12.76 UK gal) Stop the machine so that drain plug (3) is directly at the bottom.
Page 251: Clean Power Train Case Breather
MAINTENANCE SERVICE PROCEDURE CLEAN POWER TRAIN CASE BREATHER Remove the breather and wash out dust remaining inside with diesel oil and flushing oil. Power train case breather (1 place) Remove the inspection cover (2) at bottom right of the opera- tor's seat.
Page 252: Replace Corrosion Resistor Cartridge
After replacing the cartridge, run the engine, and check for any leakage of water from the filter seal surface. If any water leakage is found, check the tightening of the filter cartridge. CHECK ALL TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. GREASE TENSION PULLEY ASSEMBLY (1 PLACE) Add grease through the grease fitting until grease comes out from the relief valve.
Page 253: Check, Clean Fuel Strainer
MAINTENANCE SERVICE PROCEDURE CHECK, CLEAN FUEL STRAINER Tighten fuel supply valve (1) at the bottom of the fuel tank, remove cap (2), and wash the strainer and strainer case. The strainer forms one unit with the cap. After checking and cleaning, set the strainer in the case, then tighten cap (2).
Page 254: Replace Charge Filter Element
Remove spring (5), then take out element (6) . Clean the removed parts and the inside of filter case (7), then install a new element. Use a genuine Komatsu element. Install inspection cover (2) with bolt (1). 4-63...
Page 255: Grease Dler Adjustment Rod
Check for any loose or damaged bolts.If any bolt is loose, tighten to a torque of 926.7 ± 103.0 Nm (94.5 ± 10.5 kgm, 683.5 ± 75.9 lbft). If any bolt is damaged, replace it with a genuine Komatsu bolt. 4-64...
Page 256: Every 2000 Hours Service
When loosening drain plug (3), be careful not to get oil on yourself. Remove element (9). Clean the removed parts and the inside of the case, then install the new element. Use a genuine Komatsu element. 4-65...
Page 257: Check Play Of Turbocharger Rotor
CHECK ALTERNATOR, STARTING MOTOR The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently,carry out inspection every 1000 hours.
Page 258: Change Oil In Damper Case, Clean Damper Breather
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER WARNING The oil is at high temperature immediately after the machine has been operated.Wait for the oil to cool down before carrying out maintenance. The undercover is heavy.Do not go directly under the cover when opening or closing it. When remov- ing bolts (4), carry out the operation at the rear of the point immediately under the cover so that it is possible to escape at any time.
Page 259: Check Pivot Bearing Oil Level, Add Oil
Install plug (1). CHECK INJECTOR Check the color of the exhaust gasa visually. If there is any abnormally in the exhaust gas color, contact your Komatsu distributor for inspection. For details, see "TROUBLESHOOTING (PAGE 3-129)" "Exhaust color is black". 4-68...
Page 260: Every 4000 Hours Service
Komatsu distributor for disassembly and repair or replacement. CHECK FAN PULLEY AND TENSION PULLEY Check the pulley for play or leakage of grease.If any abnormality is found,please contact your Komatsu distributor. CHECK VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the vibration damper (1).
Page 261: Checking For Looseness Of High-Pressure Clamp, Hardening Of Rubber
Check that there is no looseness in the high-pressure clamp mounting bolts (1) - (15) in the drawing on the next page. Check visually and feel with your finger to check that the rubber has not hardened. If there is any problem, the problem part must be replaced. In such a case, please contact your Komatsu distributor. NOTICE...
Page 262: Checking For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
If there is any problem, the problem part must be replaced. In such a case, please contact your Komatsu distributor.
Page 263: Every 8000 Hours Service
Maintenance for every 10, 100, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Please contact your Komatsu distributor to have the engine high-pressure clamp replaced. REPLACE FUEL SPLAY PREVENTION CAP Please contact your Komatsu distributor to have the fuel spray prevention cap replaced. 4-72...
Page 264: Specifications
SPECIFICATIONS...
Page 265 (without operator) Blade (straight tiltdozer) kg(lb) 4,900 (10,805) Unit weight (including cylinder) Ripper unit weight kg(lb) 3,710 (8,181) Name of engine — Komatsu SA6D140E-3 diesel engine Engine horsepower Kw{HP}/rpm 231{310}/1,900 Overall length mm(ft in) 8,155(26’9") Overall height mm(ft in) 3,500(11’6")
Page 266: Attachments And Options
ATTACHMENTS OPTIONS WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 267: 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 268 Stay in a safe place where there is no danger if the load should fall. NOTICE Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified per- son. For details of removal and installation operations, contact your Komatsu distributor.
Page 269: Introduction Of Optional Parts And Attachments
Track shoes Wide shoe width 710 mm (28") Heavy-duty shoe width 610 mm (24") Heavy-duty shoe width 660 mm (26") Ripper point Reversible fan Cap with lock Headrest Various other optional parts are available, so please contact your Komatsu distributor.
Page 270: Handling Headrest
ATTACHMENTS AND OPTIONS HANDLING HEADREST HANDLING HEADREST Use the headrest with the headrest pushed down to the lowest position.
Page 271: Handling Reversible Fan
ATTACHMENTS AND OPTIONS HANDLING REVERSIBLE FAN HANDLING REVERSIBLE FAN REVERSING REVERSIBLE FAN When reversing the reversible fan in cold weather, do as fol- lows. Loosen bolt (2), then remove cover (1) on the right side of the radiator guard. A hold for inserting the tool can be seen.
Page 272: Handling Cap With Lock
ATTACHMENTS AND OPTIONS HANDLING CAP WITH LOCK HANDLING CAP WITH LOCK OPENING AND CLOSING LOCKABLE CAP Lock-type caps are available for the radiator water filler cap, fuel tank filler cap, power train case oil filler cap, hydraulic tank oil filler cap, and hydraulic tank breather cap. The cap opening and closing method is as follows. WHEN OPENING CAP Insert the key.
Page 273: Procedure For Selecting Ripper Point
ATTACHMENTS AND OPTIONS PROCEDURE FOR SELECTING RIPPER POINT PROCEDURE FOR SELECTING RIPPER POINT PROCEDURE FOR SELECTING RIPPER POINT...
Page 274: Index
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ............ 4-40 CARRYING OUT KOWA CHECK, ADJUST AIR CONDITIONER ....4-37 (Komatsu Oil Wear Analysis) ......4-7 CHECK, ADJUST ALTERNATOR DRIVE CAUTION ITEMS ..........3-9 BELT TENSION ..........4-49 CHANGE OIL IN DAMPER CASE, CHECK, CLEAN AND REPLACE CLEAN DAMPER BREATHER .......
Page 275 INDEX CHECKING FOR MISSING FUEL SPRAY ENGINE SERIAL NO. PLATE AND POSITION ..1-8 PREVENTION CAP, HARDENING OF ENSURE GOOD VISIBILITY ......2-17 RUBBER ............4-71 EVERY 1000 HOURS SERVICE ......4-57 CHECKING FOREIGN MATERIALS EVERY 2000 HOURS SERVICE ......4-65 DRAINED OIL ...........4-2 EVERY 250 HOURS SERVICE ......
Page 276 OUTLINE OF OIL, FUEL, COOLANT ....4-5 OUTLINE OF SERVICE ........4-5 KEEP MACHINE CLEAN ........2-11 KEEP WORK PLACE CLEAN AND TIDY ... 2-29 KOMATSU GENUINE OILS ........4-2 PARKING LEVER ..........3-31 KOMATSU GENUINE REPLACEMENTPARTS ... 4-2 PARKING MACHINE ....... 2-24, 3-103 PAY ATTENTION TO GAUGES .......
Page 277 INDEX PRECAUTIONS WHEN USING SAFETY LEVER ..........3-32 AIR CONDITIONER ........3-56 SAFETY RULES ..........2-10 PRECAUTIONS WHEN USING HAMMER ..2-32 SASH GLASS INTERMEDIATE LOCK ....3-38 PRECAUTIONS WHEN USING SERVICE PROCEDURE ........4-21 HIGH-PRESSURE GREASE TO SHIFTING BETWEEN FORWARD AND ADJUST TRACK TENSION ......2-33 REVERSE ............
Page 278 INDEX WARNING TAG ..........2-29 WASTE MATERIAL ..........2-35 WEAR PARTS ............4-9 WEAR PARTS LIST ..........4-9 WELDING INSTRUCTIONS ......... 4-2 WHEN REQUIRED ..........4-22 WHEN TOWING ..........2-28 WINDOW WASHER LIQUID ....... 2-15 WIPER SWITCH ..........3-25 WORK POSSIBLE USING BULLDOZER ..3-108 WORKING ON LOOSE GROUND ......

Komatsu D155AX-5 Operation & Maintenance Manual

Table of Contents

Foreword

Safety Information

Introduction

Necessary Information

Safety

Safety Labels

General Precautions

Precautions for Operation

Precautions for Maintenence

Operation

General View

Explanation of Components

Operation

Transportation

Cold Weather Operation

Long Term Storage

Troubleshooting

Guide to Maintenance

Outline of Service

Wear Parts

Use of Fuel, Coolant and Lubricants According to Ambient Temperature

Standard Tightening Torques for Bolts and Nuts

Periodic Replacement of Safety Critical Parts

Maintenance Schedure Chart

Service Procedure

When Required

Check before Starting

Every 250 Hours Service

Every 500 Hours Service

Every 1000 Hours Service

Every 2000 Hours Service

Every 4000 Hours Service

Every 8000 Hours Service

Specifications

Attachments and Options

General Precautions

Introduction of Optional Parts and Attachments

Handling Headrest

Handling Reversible Fan

Handling Cap with Lock

Procedure for Selecting Ripper Point

Index

Quick Links

Chapters

Need help?

Questions and answers

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Summary of Contents for Komatsu D155AX-5