Komatsu D65EX-18 Operation & Maintenance Manual
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Komatsu D65EX-18 Operation & Maintenance Manual

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Table of Contents

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BULLDOZER
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
D65EX
D65PX
D65WX
SERIAL NUMBERS
WARNING
NOTICE
TEN00653-01
-18
-18
-18
90001
and up

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Summary of Contents for Komatsu D65EX-18

  • Page 1 This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it. NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
  • Page 2 FOREWORD...
  • Page 3 It is provided on the back side of the operator's seat back. If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.

  • Page 4: Safety Information

    FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.

  • Page 5: Introduction

    INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Dozing work • Leveling work • Cutting into hard or frozen ground or ditching • Felling trees, removing stumps For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS (3-222)”.

  • Page 6: Visibility From Operator's Seat

    FOREWORD INTRODUCTION VISIBILITY FROM OPERATOR'S SEAT The visibility of this machine required by visibility standards (ISO 5006) are shown in the drawing below. Proximity visibility The figure below shows a visibility from the machine at a spot 1.0m (3 ft 3 in) away from outside the machine and 1.5m (4 ft 11 in) above the ground.

  • Page 7: Actions Taken To Meet Exhaust Gas Regulations

    This machine is equipped with the following two exhaust gas treatment systems: • Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu- rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".

  • Page 8: Product Information

    FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE This is at the bottom left at the front of the operator's seat.

  • Page 9: Service Meter Location

    PRODUCT INFORMATION FOREWORD SERVICE METER LOCATION This is displayed on the machine monitor. YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Phone/Fax Service personnel...

  • Page 10: Table Of Contents

    FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 BEFORE READING THIS MANUAL ......................1-2 SAFETY INFORMATION .......................... 1-3 INTRODUCTION ............................1-4 MAIN USE OF MACHINE ........................1-4 DIRECTIONS OF MACHINE......................1-4 VISIBILITY FROM OPERATOR'S SEAT .................... 1-5 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS..............1-6 PRODUCT INFORMATION........................
  • Page 11 OTHER TROUBLE......................... 3-286 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
  • Page 12 EVERY 4500 HOURS MAINTENANCE ................... 4-97 EVERY 8000 HOURS MAINTENANCE ................... 4-98 EVERY 9000 HOURS MAINTENANCE ................... 4-99 SPECIFICATIONS ............................5-1 SPECIFICATIONS ............................ 5-2 D65EX-18 SPECIFICATIONS ......................5-2 D65PX-18 SPECIFICATIONS ......................5-3 D65WX-18 SPECIFICATIONS ......................5-4 ATTACHMENTS AND OPTIONS ........................6-1 GENERAL PRECAUTIONS ........................6-2 PRECAUTIONS FOR SAFETY ......................
  • Page 13 TABLE OF CONTENTS FOREWORD RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS .... 7-10 INDEX................................8-1 1-12...

  • Page 14: Safety

    SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
  • Page 15 SAFETY SAFETY SAFETY SAFETY LABELS ............................2-4 LOCATION OF SAFETY LABELS......................2-5 CONTENTS OF SAFETY LABELS ......................2-6 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ..........2-11 PRECAUTIONS BEFORE STARTING OPERATION................2-11 ENSURE SAFE OPERATION ......................2-11 UNDERSTAND THE MACHINE ......................2-11 PREPARATIONS FOR SAFE OPERATION .....................2-11 PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT ..............2-11 INSPECT MACHINE .........................2-11 WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT ..........2-11...
  • Page 16 SAFETY SAFETY TOWING AND BEING TOWED....................... 2-30 PRECAUTIONS FOR TOWING AND BEING TOWED..............2-30 PRECAUTIONS FOR MAINTENANCE ......................2-31 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......... 2-31 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ........2-31 KEEP WORK PLACE CLEAN AND TIDY ..................2-31 SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE ..........

  • Page 17: Safety Labels

    If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...

  • Page 18: Location Of Safety Labels

    SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 1. Caution for operation, inspection and maintenance 9. Stop rotation during inspection and maintenance 2. Caution before moving in reverse 10. Caution for approaching while moving machine 3. Caution when leaving the operator's seat 11.

  • Page 19: Contents Of Safety Labels

    SAFETY LABELS SAFETY CONTENTS OF SAFETY LABELS Caution operation, inspection maintenance (09651-03001) Caution for safety at rear (09802-13000) Caution when leaving the operator's seat (09654-33001)
  • Page 20 SAFETY SAFETY LABELS Caution for high-temperature coolant (09668-03001) Caution for high-temperature oil (09653-03001) Caution for handling accumulator (09659-53000) Caution for adjusting track tension (09657-03003) This safety label is attached to the back of the track adjustment window cover.
  • Page 21 SAFETY LABELS SAFETY Caution for handling cable (09808-03000) Stop rotation during inspection maintenance (09667-43000) Caution for approaching while moving machine (09812-13000) Prohibition of start by short-circuiting (09842-A0481)
  • Page 22 SAFETY SAFETY LABELS Caution for handling battery (09664-30013) Caution for handling ROPS/FOPS (09620–A2171, 09620- A2001) Caution for blast site (09845-00480) (only when equipped with KOMTRAX) Caution for high-temperature parts (09817-A0753)
  • Page 23 SAFETY LABELS SAFETY Caution for handling AdBlue/DEF (09632-31800) 2-10...

  • Page 24: General Precautions Common To Operation And Maintenance

    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.

  • Page 25: Keep Machine Clean

    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY KEEP MACHINE CLEAN • If you get on or off the machine or perform inspection and maintenance on the machine with mud or oil, you may slip and fall, and it is dangerous. Wipe off any mud or oil from the machine. Always keep the machine clean.

  • Page 26: Precautions To Prevent Fire

    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE PRECAUTIONS TO PREVENT FIRE ACTIONS IF FIRE OCCURS • Turn the starting switch to OFF position, and stop the engine. • Use the handrails and steps to escape from the machine. •...
  • Page 27 Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). KDPF is a device to purify the soot in the exhaust gas. Exhaust gas temperature may increase during the purifi- cation process (regeneration).

  • Page 28: Precautions When Getting On Or Off Machine

    In addition, tighten any loose bolt of the handrails and steps. If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu dis- tributor to perform this work. •...

  • Page 29: No Jumping On Or Off Machine

    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY NO JUMPING ON OR OFF MACHINE Getting on or off the moving machine can cause serious personal injury or death. Always observe the following. • Never jump on or off the machine. Never get on or off a moving machine. •...

  • Page 30: Do Not Get Caught In Work Equipment

    • If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.

  • Page 31: Precautions When Running Engine Inside Building

    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING The engine exhaust gas contains substances that may damage your health or even cause death. Start or operate the engine in a place where there is good ventilation. If the engine or ma- chine must be operated inside a building or underground, where the ventilation is poor, take steps to ensure that the en- gine exhaust gas is removed and that ample fresh air is...

  • Page 32: Precautions For Operation

    SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...

  • Page 33: Do Not Go Close To High-Voltage Cables

    PRECAUTIONS FOR OPERATION SAFETY DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always observe the following.

  • Page 34: Check Signs And Signalman's Signals

    Prohibit anyone other than the operator from coming close to the machine during operation. • Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. 2-21...

  • Page 35: Start Engine

    PRECAUTIONS FOR OPERATION SAFETY START ENGINE USE WARNING TAGS If there is a "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is performing inspection and maintenance of the machine. If the warning tag is ignored and the machine is operated, the person performing inspection or maintenance may be caught in the rotating parts or moving parts.

  • Page 36: Precautions When Starting Engine

    SAFETY PRECAUTIONS FOR OPERATION • Before starting the engine, check that work equipment lock lever (1) and parking brake lever (2) are in LOCK positions (L). • Adjust the mirrors to have a good rear view from the oper- ator's seat. For the adjustment, see “METHOD FOR ADJUSTING MIRRORS (3-184)”.

  • Page 37: Start Engine With Jumper Cables

    PRECAUTIONS FOR OPERATION SAFETY START ENGINE WITH JUMPER CABLES If any mistake is made in the method of connecting the jumper cables, it may cause the battery to explode, so always observe the following. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cables.

  • Page 38: Precautions For Operation

    SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly, the machine will be unable to display its full perform- ance. It is dangerous and may cause serious personal injury or death. When performing the checks, move the machine to a wide area with no obstructions, and pay careful attention to the surroundings.

  • Page 39: Precautions When Traveling

    PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN TRAVELING Serious personal injury or death can result from tipping over of the traveling machine or its accidental contact. Always observe the following. • When driving the machine or performing operations, always keep a safe distance from people, structures, or other machines to avoid coming into contact with them.

  • Page 40: Precautions When Traveling On Slopes

    SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always observe the following. • Never turn the key in the starting switch to OFF position when the machine is traveling downhill. If the engine stops when the machine is traveling, it may become impossible to operate the steering, and this may cause serious per- sonal injury or death.

  • Page 41: Precautions When Operating On Snow Or Frozen Surfaces

    PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES • Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ma- chine, and do not perform abrupt lever operation. Machine may slip even on a slight slope. Be particularly careful when working on slopes.

  • Page 42: Precautions For Transportation

    • This machine needs to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is wrong when loading or unloading the machine, it is dangerous that the machine may tip over or fall.

  • Page 43: Towing And Being Towed

    PRECAUTIONS FOR OPERATION SAFETY TOWING AND BEING TOWED PRECAUTIONS FOR TOWING AND BEING TOWED Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or death.

  • Page 44: Precautions For Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the "DAN- GER! Do NOT operate!" warning tag. If there is a "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.

  • Page 45: Stop Engine Before Carrying Out Inspection And Maintenance

    PRECAUTIONS FOR MAINTENANCE SAFETY STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death. Always observe the fol- lowing.

  • Page 46: Workers For Maintenance When Engine Is Running

    SAFETY PRECAUTIONS FOR MAINTENANCE 2 WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent accident, do not perform maintenance with the engine running. When it is necessary to perform the maintenance with the engine running, always observe the following. • One worker must always sit in the operator's seat and be ready to stop the engine at any time.

  • Page 47: Work On Machine

    PRECAUTIONS FOR MAINTENANCE SAFETY WORK ON MACHINE • When performing maintenance work on the machine, maintain the foothold clean and orderly to prevent falling. Always observe the followings. • Avoid spilling of oil and grease. • Do not litter the tools. •...

  • Page 48: Precautions For Inspection And Maintenance

    SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE TURN BATTERY DISCONNECT SWITCH TO OFF POSITION In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key. If you check and handle battery without turning battery disconnect switch to OFF position, serious personal in- jury or death by such as an electric shock may occur.

  • Page 49: Precautions When Using Hammer

    PRECAUTIONS FOR MAINTENANCE SAFETY Danger of sparks Sparks may be generated and they can cause a fire. Always observe the following. • Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools lying around near the battery.

  • Page 50: Precautions For High-Temperature Parts

    If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.

  • Page 51: Precautions For High Voltage

    PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR HIGH VOLTAGE When the engine is running and immediately after it is stopped, high voltage is generated inside the engine controller and the engine injector, and there is danger of electric shock. Never touch the inside of the engine controller or the injector part of the engine.

  • Page 52: Do Not Disassemble Recoil Spring

    If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. If it is necessary to disassemble it, ask your Komatsu distributor to perform the work. HANDLE ACCUMULATOR This machine is equipped with an accumulator.

  • Page 53: Precautions For Disposing Of Waste Materials

    PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution, pay full attention to the way to dispose of waste materials. • Always drain the oil from your machine in containers. Nev- er drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.

  • Page 54: Precautions For Adblue/Def

    SAFETY PRECAUTIONS FOR AdBlue/DEF PRECAUTIONS FOR AdBlue/DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING AdBlue/DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require immediate action: •...

  • Page 56: Operation

    OPERATION Please read and make sure that you understand the SAFETY section before reading this section.

  • Page 57: General View

    GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (Sigma dozer) (Power angle power tilt dozer) (1) Blade (6) Blade tilt cylinder (2) Blade lift cylinder (7) Idler (3) Sprocket (8) Frame (4) Track (9) Track frame (5) ROPS cab (10) Blade angle cylinder...
  • Page 58 OPERATION GENERAL VIEW (11) SCR (15) AdBlue/DEF pump (12) AdBlue/DEF injector (16) Battery disconnect switch (13) Komatsu Closed Crankcase Ventilation (hereafter (17) System operating lamp KCCV) ventilator (18) AdBlue/DEF tank (14) Komatsu Diesel Particulate Filter (hereafter KDPF)

  • Page 59: Controls And Gauges Names

    GENERAL VIEW OPERATION CONTROLS AND GAUGES NAMES (1) Cigarette lighter (9) Starting switch (2) Parking brake lever (10) Brake pedal (3) Fuel control dial (11) Decelerator pedal (4) Joystick (steering, directional and gear shift lever) (12) Work equipment lock lever (5) Rear lamp switch (13) Blade control lever (6) Headlamp switch...
  • Page 60 OPERATION GENERAL VIEW MACHINE MONITOR EQUIPMENT NAME AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Air conditioner control switch (17) Message display (2) Buzzer cancel switch (18) Operation mode pilot lamp (3) Operation mode selector switch (19) Air conditioner pilot lamp (4) Gear-shift mode selector switch (20) Preheating pilot lamp...

  • Page 61: Explanation Of Components

    EXPLANATION OF COMPONENTS OPERATION EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen (1) Warning display...
  • Page 62 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION When camera is not set • When the starting switch is turned to ON position, the opening screen GG is displayed. •...
  • Page 63 EXPLANATION OF COMPONENTS OPERATION When camera is set • When the starting switch is turned to ON position, the opening screen GG is displayed. • After the opening screen GG is displayed for 2 seconds, the screen switches to the camera image FF. •...
  • Page 64 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While engine shutdown secondary switch (1) is ON (engine is stopped), when the starting switch is turned to ON position, the screen shown in the figure is displayed and engine does not start.
  • Page 65 End screen when any message has been re- ceived If there is any message from your Komatsu distributor, it is dis- played on the end screen. In this case, turn the starting switch to ON position to re-check the message, and if the message is requesting a response, make a reply to it.
  • Page 66 F1, and the screen changes to the Check Before Starting screen BB without inputting ID number. REMARK • Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identifica- tion function. • Depending on the set value of ID holding time, even if in-...
  • Page 67 Be careful not to use it for the purpose of security enhance- ment. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person.
  • Page 68 OPERATION EXPLANATION OF COMPONENTS If there is any abnormality currently generated, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the current abnormality. The “Current Abnormality” screen is displayed. 3-13...
  • Page 69 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any abnormality occurs during operation, the standard screen AA changes to the abnormality screen EE. If there is any error existing, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the current abnormality.
  • Page 70 OPERATION EXPLANATION OF COMPONENTS WARNING DISPLAY NOTICE Appearance of any of action levels “L01” to “L04” on the machine monitor indicates presence of an ab- normality the machine. Take appropriate actions following the list of action level displays and remedies. The caution lamp that lights up in red when an action level is displayed warns operator to stop the ma- chine urgently, stop or pause the current operation.
  • Page 71 │ no load or stop it. Sounds inter- Lights up in │ mittently If the condition is not improved, ask your Komatsu distributor │ for inspection and maintenance. │ Some functions may be restricted from use, but the machine ↓...
  • Page 72 OPERATION EXPLANATION OF COMPONENTS CAUTION LAMP LIST NOTICE • These caution lamps do not guarantee the condition of the machine. Do not simply rely on the caution lamp when performing checks before starting (start-up inspec- tion). Always get off the machine and check each item directly. •...
  • Page 73 EXPLANATION OF COMPONENTS OPERATION Display color/Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Abnormal Abnormal KDPF system caution lamp (L04, L03) (L01) Abnormal Accumulated KDPF soot accumulation caution lamp (L03) (L01) Abnormal Sensing is AdBlue/DEF level caution lamp Normal disabled (L04, L03)
  • Page 74 OPERATION EXPLANATION OF COMPONENTS Display color/Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Abnormal Air conditioner system caution lamp (L01) Due time is Maintenance time caution lamp Notice over Seat belt is Seat belt caution lamp not fastened For the meaning of each caution lamp and the action to take for it, see the section of each caution lamp.
  • Page 75 EXPLANATION OF COMPONENTS OPERATION CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated, “!” is displayed on top of switch F5. While “!” is displayed, press switch F5 to shift the monitor dis- play screen to the “Current Abnormality” screen. Take appropriate remedies according to the displayed mes- sage.
  • Page 76 OPERATION EXPLANATION OF COMPONENTS ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature. When abnormal The caution lamp lights up in red and indicates action level “L02”. The engine coolant temperature is abnormally high. While this lamp is lit, the overheat prevention system is auto- matically actuated and the engine speed drops.
  • Page 77 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
  • Page 78 Some functions may be restricted for use, but the machine can operate. When you finish the operation, always have the inspection and maintenance performed. As needed, ask your Komatsu distributor for inspection and maintenance. BRAKE SYSTEM CAUTION LAMP The brake system caution lamp warns about abnormality in the brake system.
  • Page 79 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
  • Page 80 Much soot is accumulated in KDPF, however, the operation can be performed. After the operation is finished, move the machine to a safe place and perform manual stationary regeneration. REMARK For details of the manual stationary regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-128)”. 3-25...
  • Page 81 EXPLANATION OF COMPONENTS OPERATION AdBlue/DEF LEVEL CAUTION LAMP AdBlue/DEF level caution lamp alerts when AdBlue/DEF tank level becomes low. Whenever the caution lamp lights up in red, immediately add AdBlue/DEF. Fault conditions that result in activation of the Inducement strat- egy for engine derates to prompt to maintain or repair the emis- sion control system.
  • Page 82 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the work, move the machine to a safe place, and then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
  • Page 83 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the work, move the machine to a safe place, and then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
  • Page 84 Charging is not be performed normally while the engine is run- ning. Stop the engine and check the alternator belt and air condition- er compressor belt for damage, then ask your Komatsu distrib- utor for inspection and maintenance. For detail, see “OTHER TROUBLE (3-286)”.
  • Page 85 Air conditioner system caution lamp warns about abnormality in air conditioner system. When abnormal The caution lamp lights up in yellow and indicates action level “L01”. The air conditioner system has abnormality. Ask your Komatsu distributor for inspection and maintenance as soon as possible. 3-30...
  • Page 86 • The lighting time of maintenance due time notice (yellow) has been initially set to 30 hours, but it can be changed. To change the setting, ask your Komatsu distributor. • For operations on the “Maintenance” screen, see “MAIN- TENANCE SCREEN SETTING (3-77)”.
  • Page 87 EXPLANATION OF COMPONENTS OPERATION PILOT DISPLAY AND METER DISPLAY Pilot display (1) Engine stop pilot lamp (8) Air conditioner pilot lamp (2) Parking brake pilot lamp (9) Preheating pilot lamp (3) Work equipment lock pilot lamp (10) Fan reverse pilot lamp (4) Aftertreatment devices regeneration pilot lamp (11) Reverse travel slow mode pilot lamp (5) Aftertreatment devices regeneration disable pilot...
  • Page 88 Pilot lamp goes out: Air conditioner OFF MESSAGE DISPLAY The User Message is displayed when there is a message from Komatsu. To read the message, see “MESSAGE DISPLAY (3-93)”. Lights up in green (A): There is unread message. Lights up in blue (B): There is any read message to which no reply is made.
  • Page 89 When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to the regeneration disable to prevent fire hazards due to highly heated exhaust gas during Aftertreat- ment Devices Regeneration. For details of the setting method, see “HANDLE Komatsu Diesel Partic- ulate Filter (KDPF) (3-128)”.
  • Page 90 For the procedures of cancellation of the regeneration disable setting, and setting of manual stationary regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-128)”. WORK EQUIPMENT LOCK PILOT LAMP The work equipment lock pilot lamp lights up when the work equipment lock lever is in LOCK position.
  • Page 91 EXPLANATION OF COMPONENTS OPERATION GUIDANCE DISPLAY The guidance for energy saving operation to reduce the fuel consumption may be displayed during operation. The details of the guidance are as follows: Idling stop guidance If no operation is performed for more than 5 minutes, and the engine is idling, the idling stop message is displayed on the machine monitor.
  • Page 92 OPERATION EXPLANATION OF COMPONENTS Overload prevention guidance If the machine is overloaded during work, overload prevention message is displayed on the machine monitor. Fuel consumption can be reduced by avoiding shoe slip or op- erating the machine in the green zone of ECO gauge. Overload prevention guidance goes out more than 5 seconds later or when switch F5 is pressed.
  • Page 93 EXPLANATION OF COMPONENTS OPERATION Engine stop operation during the aftertreatment devices regeneration guidance Immediately after starting aftertreatment devices regeneration, the information about engine stop operation dur- ing the aftertreatment devices regeneration is displayed on the machine monitor. When stopping the engine during aftertreatment devices regen- eration, stop the regeneration first according to “PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISA- BLE SETTING (3-135)”, then stop the engine after running it at...
  • Page 94 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY MULTI GAUGE The multi gauge can display various items. As an example, dis- play of the engine tachometer is explained below. If the indicator is in green range during operations, it is normal. When the indicator goes beyond (A) of red range during opera- tions, the engine speed is too high.
  • Page 95 EXPLANATION OF COMPONENTS OPERATION POWER TRAIN OIL TEMPERATURE GAUGE The power train oil temperature gauge indicates the power train oil temperature. If the indicator is in green range during operations, it is normal. If the indicator goes beyond (A) of red range during operations, the overheat prevention system operates.
  • Page 96 OPERATION EXPLANATION OF COMPONENTS HYDRAULIC OIL TEMPERATURE GAUGE Hydraulic oil temperature gauge shows the hydraulic oil tem- perature. If the indicator is in green range during operations, it is normal. If the indicator goes beyond red range (A) during operations, the overheat prevention system operates.
  • Page 97 EXPLANATION OF COMPONENTS OPERATION SERVICE METER/CLOCK The service meter/clock shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even when the machine is not moving. The service meter advances 0.1 every 6 operation minutes, regardless of the engine speed.
  • Page 98 OPERATION EXPLANATION OF COMPONENTS ECO GAUGE / DRAWBAR PULL GAUGE The ECO gauge/ drawbar pull gauge displays ECO gauge (in- stantaneous fuel consumption) (C) or drawbar pull gauge (work load) (D). The instantaneous fuel consumption means the fuel consump- tion rate at each moment, which varies with the work load and engine speed.
  • Page 99 EXPLANATION OF COMPONENTS OPERATION AdBlue/DEF LEVEL GAUGE AdBlue/DEF level gauge indicates the remaining level of AdBl- ue/DEF. If the indicator is in green range during operations, it is normal. If the indicator comes close to (A) of red range during opera- tion, check and add AdBlue/DEF.
  • Page 100 OPERATION EXPLANATION OF COMPONENTS MONITOR SWITCHES (1) Function switch (5) Gear-shift mode selector switch (2) Air conditioner switch (6) Customize switch (3) Buzzer cancel switch (7) Reverse travel slow mode switch (4) Operation mode selector switch FUNCTION SWITCHES AND GUIDANCE ICONS •...
  • Page 101 EXPLANATION OF COMPONENTS OPERATION (B) Switch F3: Camera image selector switch. (C) Switch F4: Service meter / clock display selector switch (D) Switch F5: Current Abnormality display switch (Only while caution lamp is lit) (E) Switch F5: Energy saving (ECO) guidance erase switch (While ECO guidance is displayed) (F) Switch F6: User menu display switch Guidance icons and their functions differ with the contents of the displayed screen, but representative guidance...
  • Page 102 OPERATION EXPLANATION OF COMPONENTS (K) Switch F5: To cancel any change and return to the previous screen. (L) Switch F6: To decide any selection and change contents and to advance to the next screen. REMARK • Even if guidance icons are of the same shape, their display positions and corresponding function switches may differ according to screens to be displayed.
  • Page 103 EXPLANATION OF COMPONENTS OPERATION CUSTOMIZE SWITCH CAUTION To ensure safety, always stop the machine before operating the customize mode. Press the customize switch, and the “Mode Select” screen is displayed. On the “Mode Select” screen, you can set and save the follow- ing items as desired.
  • Page 104 OPERATION EXPLANATION OF COMPONENTS Press switch F3 or F4 to move the yellow cursor to a mem- ory number (“M1” to “M5”) to save, and press switch F6. The setting is saved by the above operation. Memory - call up Press switch F1 on the “Mode Select”...
  • Page 105 EXPLANATION OF COMPONENTS OPERATION REVERSE SLOW MODE SWITCH The reverse slow mode switch is used for setting and canceling the reverse slow mode. While the reverse slow mode is set, reverse slow mode pilot lamp lights up on the screen of the machine monitor. When the reverse slow mode is set, it is possible to throttle down the engine speed automatically to decrease the reverse speed.
  • Page 106 OPERATION EXPLANATION OF COMPONENTS FUNCTION SWITCHES The operation of the function switches in the standard screen CAMERA IMAGE SELECTOR SWITCH On the standard screen, press switch F3 to switch to the cam- era image display. • On machines not equipped with a camera, the guidance icon related to switch F3 is not displayed.
  • Page 107 EXPLANATION OF COMPONENTS OPERATION Other mode operations while camera image is displayed Even during the camera image is displayed, it is possible to op- erate following modes. • The air conditioner can be operated. When the air conditioner switch is operated, the screen switches to the air conditioner control screen.
  • Page 108 OPERATION EXPLANATION OF COMPONENTS • It is possible to change the customize setting by pressing the customize switch. For the customize switch, see “CUSTOMIZE SWITCH (3-48)”. After the customize setting, the screen automatically re- turns to the standard screen. • It is possible to stop the alarm buzzer for the warning item where there is an abnormality, by pressing the buzzer can- cel switch.
  • Page 109 EXPLANATION OF COMPONENTS OPERATION • If the caution lamp is displayed, press switch F6 to return to the standard screen, and check the content of the ab- normality or warning display. While the caution lamp is flashing, if no lever is operated for 10 seconds or more, the screen automatically returns to the standard screen.
  • Page 110 OPERATION EXPLANATION OF COMPONENTS MULTI GAUGE SELECTOR SWITCH Multi-gauge display items can be switched by pressing the function switch F2. METHOD FOR USING MULTI GAUGE The multi-gauge can display the following items. Multi-gauge selection item Remarks Engine speed There is a caution Machine speed Work equipment pump pressure Battery voltage...
  • Page 111 EXPLANATION OF COMPONENTS OPERATION Travel speed (1) 0 km/h (0 MPH) (2) 5 km/h (3.1 MPH) (3) 10 km/h (6.2 MPH) (4) 15 km/h (9.3 MPH) Work equipment pump pressure (1) 0 MPa {0 kg/cm , 0 PSI} (2) 10 MPa {102 kg/cm , 1450 PSI} (3) 20 MPa {204 kg/cm , 2900 PSI} (4) 30 MPa {306 kg/cm , 4350 PSI} (5) 40 MPa {408 kg/cm , 5800 PSI}...
  • Page 112 OPERATION EXPLANATION OF COMPONENTS Pitch graph Horizontal axis (X) indicates the time, and vertical axis (Y) indi- cates the pitch angle of the machine. The graphs on the screen are updated and scrolled to the left at intervals of several seconds. (The latest information is dis- played at the right end.) Clock display 3-57...
  • Page 113 EXPLANATION OF COMPONENTS OPERATION USER MENU DISPLAY SWITCH On the standard screen, press switch F6 to display the user menu screen on which you can make various settings for the machine in the monitor display. USER MENU The user menu consists of the following kinds. Press switches F1 and F2 to move to right and left for selecting menu screens.
  • Page 114 OPERATION EXPLANATION OF COMPONENTS (b) “Machine Setting” • Fan reverse mode • Auto idle stop timer setting (c) “Aftertreatment Devices Regeneration” • Setting for regeneration disable • Operation of manual stationary regeneration (d) “SCR Information” • Check of AdBlue/DEF level •...
  • Page 115 EXPLANATION OF COMPONENTS OPERATION (g) Mail Check • Check of mail contents and reply to mail Operation on user menu screen On the user menu screen, it is possible to perform the following operations with switches F1 to F6. F1: Moves to the left menu. When on the left end menu, it moves to the right end menu.
  • Page 116 OPERATION EXPLANATION OF COMPONENTS ECO GUIDANCE Each item of Energy Saving Guidance menu (a) is used for dis- playing and setting the notification relevant to energy saving. CHECK OPERATION RECORDS Select the Operation Records (1) from the Energy Saving Guid- ance menu screen, then press switch F6.
  • Page 117 EXPLANATION OF COMPONENTS OPERATION CHECK ECO GUIDANCE RECORD Select “ECO Guidance Records” (2) from “Energy Saving Guid- ance” screen, then press switch F6. On the “ECO Guidance Records” menu, display the frequency of display of the ECO guidance on a daily basis or during the split measurement period.
  • Page 118 OPERATION EXPLANATION OF COMPONENTS CHECK FUEL CONSUMPTION RECORD Select the Average Fuel Consumption Record (3) from the En- ergy Saving Guidance menu screen, then press switch F6. On the Average Fuel Consumption Record menu, display the graph of hourly average fuel consumption during the last 12 hours or the graph of daily fuel consumption during the last 1 week.
  • Page 119 EXPLANATION OF COMPONENTS OPERATION Switching of displayed graph Press F2 on the Average Fuel Consumption Record screen to change the currently displayed graph to another. REMARK There are 2 types of graphs. One shows hourly average fuel consumption during the last 12 hours and the other is daily average fuel consumption during the last 1 week.
  • Page 120 OPERATION EXPLANATION OF COMPONENTS CHANGE DISPLAY SETTING Select Configurations (4) from the Energy Saving Guidance menu screen, then press switch F6. On the Configurations menu, following operations are availa- ble. • Setting the Average Fuel Consumption Display • Switching ON/OFF of the ECO Gauge Display •...
  • Page 121 EXPLANATION OF COMPONENTS OPERATION SET DISPLAY OF FUEL CONSUMPTION GAUGE It is possible to change the display of fuel consumption gauge (5) and the setting of Display/Non-display. Select “Average Fuel Consumption Display” (6) from “Con- figurations” screen, then press switch F6. On this screen, it is possible to perform the following oper- ations with switches F3 to F6.
  • Page 122 OPERATION EXPLANATION OF COMPONENTS REMARK When you select the split measurement, measurement stop switch F1 (“STOP”) is displayed on the “Operation Records” screen and the “ECO Guidance Records” screen. When you stop the measurement, select “Operation Records” (1) screen or “ECO Guidance Records” (2) screen on “Energy Saving Guidance”...
  • Page 123 EXPLANATION OF COMPONENTS OPERATION SWITCH DISPLAY/NON-DISPLAY OF ECO GAUGE You can specify the item to be displayed on display (7) of the standard screen. Select “ECO Gauge display” (8) from “Configurations” screen, then press switch F6. The “ECO Gauge Display” screen appears. “Traction”: Displays drawbar pull gauge (A) on the stand- ard screen.
  • Page 124 OPERATION EXPLANATION OF COMPONENTS SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE It is possible to change the target fuel consumption value (the upper limit value of the green range) of the ECO gauge (7). Select the ECO Gauge Display Fuel Target Value (9) on the Configurations screen, then press switch F6.
  • Page 125 EXPLANATION OF COMPONENTS OPERATION SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE It is possible to change the setting of Display/Non-display of ECO guidance (10). Select “ECO Guidance display” (11) from “Configurations” screen, then press switch F6. “ECO Guidance Display” setting screen appears. ON: Displays ECO Guidance (10) on the standard screen.
  • Page 126 OPERATION EXPLANATION OF COMPONENTS SWITCH DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY IS OFF It is possible to change the setting of Display/Non-display of guidance (12) when the starting key is turned off. Select ECO Guidance Display at Key OFF (13) from the Configurations screen, then press switch F6.
  • Page 127 EXPLANATION OF COMPONENTS OPERATION MACHINE SETTINGS Each item of this menu (b) is used for setting items of machine. REVERSE HYDRAULIC FAN NOTICE • After stopping the engine, check around the engine for sticking dry leaves or dirt. In particular, carefully check around the exhaust mani- fold and turbocharger for sticking dirt which can cause a fire.
  • Page 128 OPERATION EXPLANATION OF COMPONENTS Select “Fan Reverse Mode” (1) on “Machine Setting” menu (b) screen. Press switch F6. If the parking brake lever or work equipment lock lever is in FREE position or the engine is running, the screen shown in the figure is displayed and the fan rotation is not re- versed.
  • Page 129 EXPLANATION OF COMPONENTS OPERATION If the parking brake lever or work equipment lock lever is set to FREE position while the fan is rotated in reverse, the screen shown in the figure is displayed. In this case, stop the fan reverse rotation by returning the parking brake lock lever and work equipment lock lever to LOCK positions or by pressing switch F5.
  • Page 130 OPERATION EXPLANATION OF COMPONENTS Select “Auto Idle Stop Timer Setting” (2) on the “Machine Setting” menu (b) screen, and then press switch F6. Select the set time on the “Auto Idle Stop Timer Setting” screen shown, and then press switch F6. On “Auto Idle Stop Timer Setting screen”, it is possible to perform the following operations with switches F3 to F6.
  • Page 131 Aftertreatment Devices Regeneration. For details of Aftertreatment Devices Regeneration, see “HAN- DLE Komatsu Diesel Particulate Filter (KDPF) (3-128)”. The operation methods and the contents of the display of KDPF regeneration and urea SCR regeneration are common.
  • Page 132 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE SCREEN SETTING Each item of setting menu (e) on “Maintenance” screen is used for displaying and setting the notification relevant to mainte- nance. The items on the “maintenance” display are as follows. Air Cleaner Cleaning or Change Coolant Change Fuel Prefilter Change Engine Oil Change...
  • Page 133 • If you want to change the setting for the maintenance time or maintenance notice time (initial setting: 30 hours), consult your Komatsu distributor. Operations on the “Maintenance Due Time Reset” screen On the “Maintenance” screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the “Maintenance Due Time Reset”...
  • Page 134 OPERATION EXPLANATION OF COMPONENTS MONITOR SETTINGS Each item of monitor setting menu (f) is to make settings for the monitor. SCREEN ADJUSTMENT Use the screen adjustment menu to adjust brightness of the monitor screen. Select screen adjustment (1) on the monitor setting menu screen, then press switch F6.
  • Page 135 The guide lines indicate blade width lines and a line 5 m {16 ft 5 in} away from the rear of the machine. When changing the blade, ask your Komatsu distributor for adjustment of the camera screen. Select camera screen adjustment on the monitor setting menu screen.
  • Page 136 OPERATION EXPLANATION OF COMPONENTS ADJUST CAMERA IMAGE BRIGHTNESS Select Brightness Adjustment on the Camera Screen Ad- justment menu. Press switch F6. Use switches F2 to F6 to adjust brightness of the screen. F2: Resets an adjusted value to default value. F3: Moves the indicator to the left by one notch.
  • Page 137 EXPLANATION OF COMPONENTS OPERATION SET DISPLAY MODE (Reverse Synchronization setting) Select the display mode on the Screen Adjustment (Cam- era) screen. Press switch F6. The Camera View Mode setting screen is displayed. • Normal: Switch F2 of the function key is used to change the screen to the camera screen.
  • Page 138 OPERATION EXPLANATION OF COMPONENTS SET GUIDE LINE DISPLAY MODE Select the Guide Line Display Mode on the Screen Adjust- ment (Camera) screen. Press switch F6. The Guide Line Display Mode setting screen is displayed. • OFF: Guide lines (Outline (A), Center Line (B)) are not displayed.
  • Page 139 EXPLANATION OF COMPONENTS OPERATION CLOCK ADJUSTMENT The Clock Adjustment menu is used to change the setting of the clock displayed on the standard screen of the monitor. Select clock adjustment (3) on the Monitor Setting menu screen. Press switch F6. The screen switches to the Clock Adjustment screen for selecting a menu.
  • Page 140 OPERATION EXPLANATION OF COMPONENTS CALENDAR SETTING Adjust the date of the monitor. REMARK As long as “GPS Synchronization” menu is turned on, “Calendar” menu is not selectable. Select “Calendar” (b) on “Clock Adjustment” screen, then press switch F6. The “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display (A).
  • Page 141 EXPLANATION OF COMPONENTS OPERATION TIME SETTING Adjust the time of the monitor clock. REMARK As long as “GPS Synchronization” is turned ON, “Time” menu is not selectable. Select “Time” (c) on “Clock Adjustment” screen, then press switch F6. The “Time” screen is displayed. When the hour display (D) is highlighted in yellow, operate the switches as follows to change hour display (D).
  • Page 142 OPERATION EXPLANATION OF COMPONENTS SWITCH 12H/24H DISPLAY MODE Choose either a 12-hour display (am/pm) or a 24-hour display. • 24-hour system display • 12-hour system display (AM/PM) Select “12h/24h Mode” (d) on “Clock Adjustment” screen, then press switch F6. “12h/24h Mode” screen appears. F3: Moves to the next item (1 line below).
  • Page 143 EXPLANATION OF COMPONENTS OPERATION DAYLIGHT SAVING TIME (SUMMER TIME) SETTING If “Daylight Saving Time” is turned ON, the clock display becomes 1 hour earlier. If “daylight saving time” is turned OFF, the clock display returns to the set time. Select “Daylight Saving Time” (e) on “Clock Adjustment” screen, then press switch F6.
  • Page 144 OPERATION EXPLANATION OF COMPONENTS LANGUAGE SETTINGS On the language setting menu, it is possible to select the language used on the monitor display. The languages that can be selected are as follows. English, Japanese, French, Spanish, Portuguese, Italian, German, Swedish, Dutch, Danish, Norwegian, Fin- nish, Icelandic, Czech, Hungarian, Polish, Slovak, Slovene, Romanian, Croatian, Estonian, Latvian, Lithuanian, Bulgarian, Greek, Turkish, Serbian Select Language (4) on the monitor setting menu, then...
  • Page 145 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID”...
  • Page 146 OPERATION EXPLANATION OF COMPONENTS The operator ID changing screen is displayed. • Input the already registered ID on the operator ID changing screen and press F6. Then, the identified ID can be changed. A message is displayed below and the screen returns to the Monitor Setting menu screen.
  • Page 147 EXPLANATION OF COMPONENTS OPERATION WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is available without SKIP, the identified ID number is not displayed in the “Operator ID” column of Monitor Setting screen. Select operator ID (5) on the Monitor Setting menu screen, then press switch F6 for 1 second.
  • Page 148 EXPLANATION OF COMPONENTS MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this User Message menu (g). When there is any message, the User Message at the top of the standard screen lights up.
  • Page 149 EXPLANATION OF COMPONENTS OPERATION CHECK MESSAGE On the standard screen, press switch F6. When there is any message, message display (1) lights While message display (1) is lit, press switch F6, and the mail confirmation menu (e) directly opens. Select the mail confirmation menu (e), and you can read the received message.

  • Page 150: Switches

    OPERATION EXPLANATION OF COMPONENTS SWITCHES (1) Cigarette lighter (24V) (6) Starting switch (2) Fuel control dial (7) Horn switch (3) Rear lamp switch (8) Room lamp switch (4) Headlamp switch (9) Wiper switch (5) Engine shutdown secondary switch STARTING SWITCH Starting switch is used to start or stop the engine.
  • Page 151 EXPLANATION OF COMPONENTS OPERATION FUEL CONTROL DIAL Fuel control dial is used to control the engine speed and out- put. (a) Low idle (MIN) The position where the dial is turned fully to the left. (b) High idle (MAX) The position where the dial is turned fully to the right. REMARK •...
  • Page 152 OPERATION EXPLANATION OF COMPONENTS WIPER SWITCH The wiper switch operates the windshield wiper. The wiper switches are as follows. (LH) Left door (FF) Front window (RH) Right door (RR) Rear window (INT) Wiper intermittent operation switch REMARK If the wiper blade is locked for some reason, the wiper stops automatically.
  • Page 153 • When installing the cab, perform the operation in accord- ance with the cab installation procedure manual held by your Komatsu distributor. (A) For left (blue) (B) For right (red) (C) For rear (black)
  • Page 154 OPERATION EXPLANATION OF COMPONENTS HEAD LAMP SWITCH The headlamp switch is used to light up the head lamp and monitor illumination. (A) Night position Lamps light up and monitor illumination is set to night mode. (B) Day position Lamps light up and monitor illumination is set to day mode. (C) OFF position Lamps go out.
  • Page 155 • Use the engine shutdown secondary switch only in an emergency. Immediately ask your Komatsu distributor for repair of the problem. • If this switch is set to the “STOP ENGINE” position by mistake while the machine is operating nor- mally, “Engine Shutdown Secondary Switch Activated”...

  • Page 156: Control Levers And Pedals

    OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS (1) Parking brake lever (5) Work equipment lock lever (2) Joystick (steering, directional and gear shift lever) (6) Blade control lever (3) Brake pedal (7) Ripper control lever (if equipped) (4) Decelerator pedal 3-101...
  • Page 157 EXPLANATION OF COMPONENTS OPERATION BLADE CONTROL LEVER The blade control lever is used to control the blade. (a) RAISE (b) HOLD (c) LOWER (d) FLOAT (A) RIGHT tilt (B) LEFT tilt BLADE CONTROL LEVER FOR SIGMA DOZER Lifting operation (a) RAISE (b) HOLD: Blade is stopped and held in this position.
  • Page 158 OPERATION EXPLANATION OF COMPONENTS Tilting operation (A) RIGHT tilt (b) HOLD: Blade is stopped and held in this position. (B) LEFT tilt Pitching operation (If equipped) Operate the blade control lever while pressing pitch button (C). (D) Pitch angle in NEUTRAL: Cutting angle is in neutral (E) FORWARD PITCH: Cutting angle is increased.
  • Page 159 EXPLANATION OF COMPONENTS OPERATION Position at which R.H. pitch cylinder is fully retracted Position at which cylinder rod is seen clear (Position at which cylinder rod starts appearing) Neutral pitch angle Forward pitch BLADE CONTROL LEVER FOR POWER ANGLE POWER TILT DOZER Lifting operation (a) RAISE (b) HOLD: Blade is stopped and held in this position.
  • Page 160 OPERATION EXPLANATION OF COMPONENTS Tilting operation (A) RIGHT tilt (b) HOLD: Blade is stopped and held in this position. (B) LEFT tilt REMARK You can perform tilting operation during angling operation, but the blade speed decreases. Select the operations according to the type of the work. Angling control Operate angle switch (L) forward and backward to angle the blade.
  • Page 161 EXPLANATION OF COMPONENTS OPERATION BRAKE PEDAL WARNING Do not rest your foot on the pedal except when you oper- ate the pedal. If you depress the brake pedal, R.H. and L.H. brakes are ap- plied simultaneously. PARKING BRAKE LEVER WARNING •...
  • Page 162 OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT LOCK LEVER WARNING • When standing up from the operator's seat, set the work equipment lock lever securely to LOCK po- sition. If it is not locked, the blade control and ripper control levers are touched by mistake, it may lead to serious accident.
  • Page 163 EXPLANATION OF COMPONENTS OPERATION JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) (PCCS LEV- Perform forward/reverse switching operation, steering opera- tion, and counter-rotation turn by using the joystick (steering, directional and gear shift lever). REMARK PCCS: Palm command control system (Electronic steering system) Forward/reverse switching operation (a) FORWARD (N) NEUTRAL...
  • Page 164 OPERATION EXPLANATION OF COMPONENTS REMARK • When the gear is shifted, the current gear speed is displayed in the gear speed display section of the ma- chine monitor. (Example) Neutral: “N” is displayed in the display section. Forward 2nd: “F2” is displayed in the display section. Reverse 3rd: “R3”...
  • Page 165 EXPLANATION OF COMPONENTS OPERATION RIPPER CONTROL LEVER (If equipped) The ripper control lever is used for operating the ripper. (a) RAISE (b) HOLD: Ripper is stopped and held in this position. (c) LOWER 3-110...

  • Page 166: Other Equipment

    OPERATION EXPLANATION OF COMPONENTS OTHER EQUIPMENT DOOR OPEN LOCK Use the door lock to fix the door in position after opening it. Push the door against the door catch (1). The door is fixed to the catch. To release the door, move lever (2) inside the cab to the front of the cab. The catch releases.
  • Page 167 EXPLANATION OF COMPONENTS OPERATION CAP AND COVER WITH LOCK Use the starting switch key to open and close the locks on the caps and covers. For the locations and opening and closing method of the cap with lock and cover, see “LOCK (3-240)”. Insert the key as far as it will go to the shoulder (A) and turn it.
  • Page 168 OPERATION EXPLANATION OF COMPONENTS POWER SUPPLY OUTLET Power source inside cab 24V power supply NOTICE Do not use this as a power supply for 12V equipment. This will cause failure of the equipment. If cigarette lighter (1) is removed, its socket can be used as a power source.
  • Page 169 EXPLANATION OF COMPONENTS OPERATION FUSE NOTICE When replacing the fuse, be sure to turn the starting switch to OFF position and, after confirming that the system operating lamp is not lit, set the battery disconnect switch key to OFF position. •...
  • Page 170 OPERATION EXPLANATION OF COMPONENTS Fuse ca- Name of circuit pacity (14) 15 A Key accessory (upstream) (15) 20 A Optional device Fuse box (2) Fuse ca- Name of circuit pacity 20 A Steering controller power supply 20 A Air conditioner power supply 20 A Controller continuous power supply 30 A Engine controller power supply (24 V) 30 A...
  • Page 171 EXPLANATION OF COMPONENTS OPERATION FUSIBLE LINK NOTICE Before replacing a fusible link, be sure to turn the starting switch to OFF position, then turn the battery disconnect switch key to OFF position. When the starting switch is turned to START position, if the starting motor does not operate, any of the electrical component in the operator's cab does not work, or the pre-heater does not work, a fusible link built in the wiring harness is suspected to be disconnected.
  • Page 172 OPERATION EXPLANATION OF COMPONENTS FIRE EXTINGUISHER (if equipped) A fire extinguisher is provided at the rear part inside the opera- tor's cab. The directions are described on the nameplate affixed to the fire extinguisher. Carefully read and understand them before- hand for an emergency.
  • Page 173 EXPLANATION OF COMPONENTS OPERATION BATTERY DISCONNECT SWITCH CAUTION • Do not operate the battery disconnect switch while the engine is running. The large current generated by the alternator may burn the electric parts and cause a fire. When operating the battery disconnect switch, always stop the engine. •...
  • Page 174 • After the starting switch has been turned off, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. • While AdBlue/DEF system devices are operating, the system operating lamp lights up to return AdBlue/DEF to the tank.
  • Page 175 EXPLANATION OF COMPONENTS OPERATION DUST INDICATOR This device notifies the operator of clogging of air cleaner ele- ment. For the cleaning method of the element, see “METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER (4-16)”. 3-120...
  • Page 176 OPERATION EXPLANATION OF COMPONENTS HANDLE ID KEY (if equipped) The starting switch keys are ID keys which have built-in IC chips, and you can start the engine only with the usual keys (black) registered in the machine. ID KEY TYPES Usual key ID key used usually to start the engine (Black) (1)
  • Page 177 (gray), or usual key (black) which is not registered in the machine. • If the ID key system has any abnormality, the ID key sys- tem abnormality screen is displayed. If this screen is dis- played, call your Komatsu distributor. 3-122...
  • Page 178 OPERATION EXPLANATION OF COMPONENTS PROCEDURES FOR CHECKING ID NUMBER OF REGISTERED NORMAL KEY (BLACK) Insert the usual key (black) in the starting switch and turn it to ON position. When the standard screen is displayed, press switch F6. Operate switches F1 and F2 to display “Monitor Setting” menu (A).
  • Page 179 EXPLANATION OF COMPONENTS OPERATION PROCEDURES FOR DELETING ID NUMBER OF REGISTERED NORMAL KEY (BLACK) After the ID key list screen is displayed, select the ID No. of a usual key which you want to delete and hold down function switch F6 for 2 seconds or more. The registered key deletion screen is displayed.
  • Page 180 OPERATION EXPLANATION OF COMPONENTS PROCEDURES FOR DELETING ID NUMBERS OF ALL THE REGISTERED NOR- MAL KEYS (BLACK) You can delete the keys registered in the machine all together. Insert registration key (gray) in the starting switch and turn it to ON position (B) to display the ID key setting screen on the monitor.
  • Page 181 EXPLANATION OF COMPONENTS OPERATION PROCEDURES FOR REGISTERING ID NUMBER OF NEW NORMAL KEY (BLACK) Insert registration key (gray) in the starting switch and turn it to ON position (B) to display the ID key setting screen on the monitor. Replace the registration key with the normal key (black) to be registered and turn it to ON position (B).
  • Page 182 OPERATION EXPLANATION OF COMPONENTS REMARK If you again register a normal key (black) which is registered al- ready, the screen shown at right is displayed. REMARK If registration fails, the screen shown at right is displayed. If this screen is displayed, repeat the registration procedure from the first.
  • Page 183 EXPLANATION OF COMPONENTS OPERATION HANDLE Komatsu Diesel Particulate Filter (KDPF) CAUTION • Exhaust gas temperature may increase higher than the previous models during aftertreatment devi- ces regeneration and the high temperature may last after the completion of regeneration. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt.
  • Page 184 OPERATION EXPLANATION OF COMPONENTS NOTICE Do not stop engine when the aftertreatment devices regeneration is activated. When stopping the engine, stop the aftertreatment devices regeneration first according to “PROCE- DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING (3-135)”, then keep en- gine running at low idle for approximately 5 minutes, and stop engine.
  • Page 185 • Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF fil- ters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
  • Page 186 OPERATION EXPLANATION OF COMPONENTS When the degree of emergency is low • If KDPF soot accumulation caution lamp (2) lights up in yellow (action level (3): “L01”), screen (A) is displayed first. • The action level goes out 2 seconds after and the screen changes to standard screen (B).
  • Page 187 EXPLANATION OF COMPONENTS OPERATION PROCEDURE FOR MANUAL STATIONARY REGENERATION CAUTION Exhaust gas temperature may increase higher than the previous models during aftertreatment devices regenera- tion. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt. Also, keep combustible materials away from the exhaust pipe outlet and around the aftertreatment devices to prevent a fire.
  • Page 188 OPERATION EXPLANATION OF COMPONENTS REMARK After switch F6 is pressed in step 6., the screen shown in the figure may be displayed. This indicates that the opera- tions in steps 1 to 4 were not performed correctly or there is trouble other than KDPF soot accumulation abnormality. After checking that the engine is running normal, the park- ing brake lever and work equipment lock lever are in LOCK position (L) and the fuel control dial is set to Low...
  • Page 189 EXPLANATION OF COMPONENTS OPERATION The screen shown in the figure is displayed during the manual stationary regeneration. It may take more than 40 minutes to complete the manual stationary regeneration. Do not touch any switch on the screen or operate fuel control dial until the regeneration is completed and the standard screen appears again.
  • Page 190 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING If there is combustible material around the machine and the active regeneration that increases the exhaust tem- perature must not be performed, the automatic active aftertreatment devices regeneration can be disabled. Al- so, the regeneration in progress can be stopped.
  • Page 191 EXPLANATION OF COMPONENTS OPERATION REMARK • When the regeneration is disabled, aftertreatment devices regeneration disable pilot lamp (2) is lit on the standard screen. • The setting of regeneration disable is canceled by turning starting switch to OFF position. When the automatic regen- eration needs to be kept disabled, perform the above pro- cedure each time you start the engine.
  • Page 192 OPERATION EXPLANATION OF COMPONENTS Select “Regeneration Disable” and then press switch F6, and the regeneration stops. REMARK The regeneration performed to protect the system may not be stopped, but this is not a failure. 3-137...
  • Page 193 EXPLANATION OF COMPONENTS OPERATION PROCEDURE FOR CANCEL OF AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING CAUTION When canceling the regeneration disable, move the machine to a safe place and check that there is no person or combustible matter around the machine, and start the cancel operation. When switch F6 is pressed on the standard screen, the “Aftertreatment Devices Regeneration”...
  • Page 194 FOR REPLACING KCCV FILTER ELEMENT (4-87)”. • If the engine is operated without KCCV filter element or if a filter element other than the Komatsu genuine element is used, the engine sucks oil and foreign ma- terial which can cause a failure. Always install Komat- su genuine KCCV filter element.
  • Page 195 Urea SCR systems by utiliz- ing visible and audible alerts, and engine power derate in addition. Alerts in Inducement of the Komatsu Urea SCR System progresses step by step starting from visual indications on the machine monitor and audible sounds to engine power derate to avoid getting into unsafe conditions.
  • Page 196 KDPF has not reached to the regeneration thresholds. For details of Aftertreatment Devices Regeneration, see “HAN- DLE Komatsu Diesel Particulate Filter (KDPF) (3-128)”. WARNING Fill ONLY AdBlue/DEF into AdBlue/DEF tank. Foreign ma- terial in the AdBlue/DEF system or urea deposits caused by evaporation may hinder operation of the devices.
  • Page 197 EXPLANATION OF COMPONENTS OPERATION Urea SCR system is equipped with a heating system to thaw frozen AdBlue/DEF once it is frozen, for example, during parking and to prevent AdBlue/DEF from freezing during operation. In case AdBlue/DEF freezes during parking, once the engine starts running the heating system automatically starts providing heat to thaw frozen AdBlue/DEF.
  • Page 198 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen displays the AdBlue/DEF level cau- tion lamp (1), the AdBlue/DEF level gauge (2), information on the Urea SCR System condition (3), and the current status of Inducement (4). If Inducement starts, stop the machine in a safe place and add AdBlue/DEF.
  • Page 199 EXPLANATION OF COMPONENTS OPERATION • Mild Inducement: The audible alert sounds in short and sharp beeps. 1 gradation of the AdBlue/DEF level gauge light up in red. The AdBlue/DEF level caution lamp (1) lights up in red. Action Level “L03” is displayed in red (5). Press F6 to display the “SCR Information”...
  • Page 200 Inducement”, the engine speed is fixed to low idle. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
  • Page 201 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen displays remaining time to the next Inducement status in the column (5), and information on the Urea SCR System condition (3), and the current status of In- ducement (4). • Warning: No audible alert. The AdBlue/DEF system caution lamp (1) lights up in yel- low.
  • Page 202 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Mild Inducement”.
  • Page 203 “Final Inducement”, the engine speed is fixed to low idle. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
  • Page 204 OPERATION EXPLANATION OF COMPONENTS If either the parking brake lever and work equipment lock lever are set to LOCK position or the joystick (steering, directional and gear shift lever) is in NEUTRAL position for over 3 sec- onds, “SCR Information” screen of the user menu will pop up automatically while the Urea SCR system is in Inducement.
  • Page 205 “Temporary Restoration from Inducement” in this man- ual. If Inducement advances to “Severe Inducement” and it becomes necessary to restore engine power, use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor.
  • Page 206 OPERATION EXPLANATION OF COMPONENTS • Final Inducement: The audible alert sounds in continuous beep. The KDPF system caution lamp (1) lights up in red. The AdBlue/DEF system caution lamp (2) lights up in red. Action level “L04” lights up in red (3) at action level display. Press F6 to display the “SCR Information”...
  • Page 207 EXPLANATION OF COMPONENTS OPERATION Press F6 to display the menu windows popping up in the bottom half of the “SCR Information”. The menu windows popping up in the bottom half of the “SCR Information” screen alternate every 15 seconds as shown in the graphics A and B.
  • Page 208 If a recurrence occurs, “Severe Inducement” will be activated. If this occurs, utilize “Temporary Restoration from Inducement” and move the machine to a safe place, and contact your Komatsu distributor. The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not cor- rected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final Inducement”...
  • Page 209 (4-90)”. • If the machine is operated without AdBlue/DEF filter attached, or with the filter other than Komatsu genuine parts, foreign materials may enter into AdBlue/DEF pump and AdBlue/DEF injector which will cause failure of the machine. Never operate the machine without AdBlue/DEF filter attached, nor use the filter other than Komatsu genuine parts.
  • Page 210 If you have to operate the machine within 12 m {39 ft 4 in} from the blasting jobsite or the remote- controlled blasting device, the power supply cable of KOMTRAX must be disconnected in advance. If you want to do this, ask your Komatsu distributor for disconnecting power supply cable of KOM- TRAX.
  • Page 211 In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com- munication. If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages.

  • Page 212: Machine Operations And Controls

    Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. • Do not get on or off the machine from the rear. Since the floor is slippery and not seen from the operator seat, it is dangerous to get on or off there.
  • Page 213 11. Check the seat belt and mounting hardware. Check the seat belt and mounting hardware for any abnormality. If any damage is found, ask your Komatsu distributor to replace it with new one. 12. Check and clean the camera (Machine with camera) Check the camera for any abnormality.
  • Page 214 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING BEFORE STARTING Always check the items in this section before starting the engine each day. METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK Perform this procedure before operating the machine. Prepare a container to catch drained fuel. Open cover (1).
  • Page 215 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI- MENT The water separator serves to separate water mixed in the fuel. Prepare a container to catch the water and sediment. Open the battery inspection cover on the left side of the machine.
  • Page 216 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • When the oil filler cap is removed, oil may spout out. After stopping the engine, wait for the oil tem- perature to go down, turn the cap slowly to release the internal pressure, then remove the cap with care.
  • Page 217 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT WARNING • Do not open the radiator cap unless necessary. When checking the coolant level, check the sub- tank when the engine is cold. • Do not remove the reservoir tank cap while the radiator coolant temperature is high. Boiling coolant may spurt out.
  • Page 218 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. Check the oil level either before engine start or at least 15 minutes after the engine stops.
  • Page 219 MACHINE OPERATIONS AND CONTROLS OPERATION Take the end of hose (2) out of the inspection window. Loosen drain plug (P) to drain excessive oil. When draining the engine oil, put a container to catch the oil under the drain plug. Check the oil level again.
  • Page 220 OPERATION MACHINE OPERATIONS AND CONTROLS Remove cover (1) on the lower rear side of the ma- chine. Place an oil container to catch oil under drain plug (P). Loosen drain plug (P) to drain excessive oil. Check the oil level again. After the oil is adjusted to a proper level, insert dipstick (G) fully into the dipstick pipe again.
  • Page 221 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
  • Page 222 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING FUEL LEVEL, ADDING FUEL WARNING When adding fuel, never spill the fuel or let it overflow. It may cause a fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand.
  • Page 223 In this case, ask your Komatsu distributor for draining of the wrong fluid and for inspection. AdBlue/DEF injector and/or AdBlue/DEF pump may need to be replaced.
  • Page 224 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the starting switch to ON position (B). Check the AdBlue/DEF level gauge on the machine moni- tor. After checking, turn the starting switch back to OFF posi- tion (A). Check that the engine is stopped. If AdBlue/DEF is insufficient, add AdBlue/DEF.
  • Page 225 MACHINE OPERATIONS AND CONTROLS OPERATION Connect AdBlue/DEF supply hose (b) to DEF contain- er (a). (c) Connecting side to the DEF container (d) Inserting side to the AdBlue/DEF filler port Insert AdBlue/DEF supply hose (b) into filler port (2). 10) Tilt DEF container (a) gradually. 11) By watching sight gauge (3), add AdBlue/DEF through filler port (2) until float (4) reaches line F (5).
  • Page 226 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • It is recommended to use a nozzle having a diameter and a length specified by ISO 22241-4 and an auto stop function to add AdBlue/DEF. When the specified nozzle is used, the magnet installed inside the filler port of the tank cancels the wrong fluid addition prevention device, and you can add AdBlue/DEF.
  • Page 227 If the lamps do not light up, a broken bulb or disconnected wire are the possible causes. Ask your Komatsu distributor for repairs. After finishing the check, turn the head lamp to OFF posi- tion (c) and turn the rear lamp to OFF position (e).
  • Page 228 Do not perform the check before starting only on the monitor. Always perform other checks before start- ing. Turn starting switch (1) to ON position (B). Check that KOMATSU mark is displayed first and then the camera screen and the basic monitor screen is displayed in order, and the buzzer sounds for approximately 2 sec- onds.
  • Page 229 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING HORN OPERATION Turn the starting switch to ON position (B). Check that the horn sounds when the horn switch is press- If the horn does not sound at all or the volume is extremely weak, a defect or broken wire is suspected, ask your Ko- matsu distributor for repair.
  • Page 230 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING BACKUP ALARM OPERATION STATUS Turn the starting switch to ON position (B). Set the parking brake lever to LOCK position (L). Set the joystick (steering, directional and gear shift lever) in REVERSE position (R). The alarm must sound immediately at this time.
  • Page 231 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR'S SEAT WARNING • When adjusting the position of the operator's seat, always set the work equipment lock lever and parking brake lever to LOCK positions to prevent any accidental contact with the control levers. •...
  • Page 232 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TILTING SEAT Pull up the tilt adjustment lever and adjust the front angle of the seat. • To raise the front of the seat, apply your weight to the rear of the seat, while pulling up lever. •...
  • Page 233 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING WEIGHT AND HEIGHT OF SEAT Pull out the crank of knob (1) under the seat and turn it so that weight indicator (2) reads the green range. You can adjust the height by turning knob (1) in the green range. X: When crank is stored Y: When crank is pulled out (for adjusting weight) Adjust the weight according to the following procedure.
  • Page 234 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING LUMBER SUPPORT Turn the adjustment knob to the right or left, and give proper tension to the waist part. The back cushion tension is increased by turning the adjust- ment knob to the right. The tension of the back cushion can be adjusted to 5 steps.
  • Page 235 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR HEATING SEAT Turn the seat heater switch ON. (a): OFF position (b): ON position The backrest and seat surface are heated. When the seat heater switch is turned ON, the heater in the seat operates. When the seat surface temperature exceeds approximately 20 °C {68 °F} , the hater is turned OFF automatically.
  • Page 236 OPERATION MACHINE OPERATIONS AND CONTROLS AIR SUSPENSION SEAT (if equipped) METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION Pull up the fore-aft adjustment lever, set the seat to the de- sired position. Fore-and-aft adjustment: 160 mm {6.3 in} (16 stages) After adjusting, release the lever. METHOD FOR RECLINING SEAT The reclining of the seat becomes large when the seat is moved forward, and it becomes smaller as the seat is moved backward.
  • Page 237 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING WEIGHT AND HEIGHT OF SEAT When adjusting the allowable weight and height of the seat, turn the starting switch to ON position since the air compressor built in the seat is used for the adjustment. NOTICE Avoid using lever (3) continuously for 1 minute or longer since such practice can damage the air com- pressor.
  • Page 238 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING SEAT DIRECTION You can change the direction of the seat to 12.5 ° on the right by pulling up the direction adjustment lever to FREE position (F) and unlock it. When using the ripper, the operator can work easily by directing the seat to the right. Pull up the direction adjustment lever to FREE position (F) and unlock it.
  • Page 239 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING MIRRORS WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may lead to a serious personal injury or death. Loosen nut (1) installed to the mirror.
  • Page 240 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) (PCCS LEVER) WARNING After moving case (2) in order to adjust the position of the joystick (steering, directional and gear shift lever) (PCCS lever), secure lock lever (1) into the notched hole, making sure it is in LOCK position. If the locking condition is unstable, when the joystick (steering, directional and gear shift lever) is oper- ated, the machine may move unexpectedly and can cause personal injury or death.
  • Page 241 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING ARMREST The R.H. and L.H. armrests of the operator's seat can be adjusted in height as shown below. After adjusting the operator's seat, adjust them to proper height. METHOD FOR ADJUSTING RIGHT ARMREST R.H.
  • Page 242 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
  • Page 243 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR UNFASTENING SEAT BELT Press button (5) in buckle (4) and remove tongue (3) from buckle (4). The belt is automatically wound in, hold grip (2) and return the belt slowly to retractable device (1). 3-188...
  • Page 244 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING • When starting the engine, check and make sure park- ing brake lever (1) and work equipment lock lever (4) are secured in LOCK position. If the work equipment 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 245 MACHINE OPERATIONS AND CONTROLS OPERATION If joystick (steering, directional and gear shift lever) (2) is in F or R, the letter “P” on gear speed display will flash. Lower the blade to the ground. For blade operation, see “BLADE CONTROL LEVER (3-102)”.
  • Page 246 If a password is set, the input display screen will be indi- cated on the machine monitor. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the password. 11. Perform the following inspection on the machine monitor.
  • Page 247 MACHINE OPERATIONS AND CONTROLS OPERATION Check that the screen will change to the preset (speed range to start) display screen in approximately 2 sec- onds, then it will change to the standard screen. • Power train oil temperature gauge (5) •...

  • Page 248: Method For Starting Engine

    OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING ENGINE METHOD FOR STARTING ENGINE IN NORMAL WEATHER WARNING • Start the engine only while sitting down in the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a fire or serious personal injury or death.
  • Page 249 MACHINE OPERATIONS AND CONTROLS OPERATION Turn starting switch key (2) to START position (C). The engine starts. When the engine starts, release the starting switch key (2). The key will return automatically to ON position (B). REMARK • White smoke may be discharged for a short time immediately after the engine is started or during the after- treatment devices regeneration in the cold season, but this is not a failure.
  • Page 250 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE • In all cases, do not turn the starting motor continuous- ly for more than 60 seconds. If the engine does not start, wait for approximately 2 minutes, then repeat the procedure from step 2. •...
  • Page 251 MACHINE OPERATIONS AND CONTROLS OPERATION Check if preheating pilot lamp (3) on the machine monitor is lit. Leave this condition until preheating pilot lamp (3) goes out. After preheating pilot lamp (3) goes out, turn the key of starting switch (2) to START position (C), and start the en- gine.
  • Page 252 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • Regardless of the ambient temperature, if the starting switch (2) is turned counterclockwise from OFF posi- tion, engine preheating pilot lamp (3) lights up and preheating starts. (Pre-heating continues while the start- ing switch (2) is held at the left.) For the details of the preheat time, see the table in step 5.

  • Page 253: Method For Operations And Checks After Starting Engine

    In that case, ask your Komatsu distributor to check the engine as soon as possible.
  • Page 254 METHOD FOR RUNNING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
  • Page 255 • (C) to (D): White range Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. REMARK The cooling fan speed varies according to the following conditions, but it is not abnormal.
  • Page 256 (C) to (D): White range REMARK If the power train oil temperature is not sufficiently high, it takes longer to reach the maximum speed. 12. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. 3-201...

  • Page 257: Method For Stopping Engine

    MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STOPPING ENGINE WARNING Keep away from the exhaust pipe immediately after stopping the engine. NOTICE • If the engine is abruptly stopped before it has cooled down, service life of the engine parts may be reduced. Do not stop the engine abruptly except in an emergen- If the engine overheats, do not stop it suddenly.
  • Page 258 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • When engine starting switch (2) is turned to OFF posi- tion, the engine stops, but the machine's main power supply is not turned off immediately. During this period, the power is supplied to the con- troller to save the operating condition and then finish the system.

  • Page 259: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine

    MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE METHOD FOR MOVING MACHINE WARNING • Before moving the machine off, check that the area around the machine is safe, then sound the horn be- fore starting.
  • Page 260 OPERATION MACHINE OPERATIONS AND CONTROLS Set blade control lever (3) to RAISE position (A) and raise the blade to 40 to 50 cm (16 to 20 in) above the ground. Set ripper control lever (4) to RAISE position (a) and raise the ripper to the upper limit. Turn fuel control dial (5) to High idle (MAX) position and in- crease the engine speed.
  • Page 261 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STOPPING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, place parking brake lever (1) in LOCK position and insert blocks underneath the track shoes to pre- vent the machine from moving.

  • Page 262: Shift Gears

    OPERATION MACHINE OPERATIONS AND CONTROLS SHIFT GEARS WARNING When the machine is traveling on a flat ground or down a slope, never set the joystick (steering, direc- tional and gear shift lever) to N (neutral) position. Always keep it in a gear speed when traveling. When traveling with the joystick (steering, directional and gear shift lever) in N (neutral) position, always decelerate, and then change the travel direction.
  • Page 263 MACHINE OPERATIONS AND CONTROLS OPERATION OUTLINE OF GEARSHIFT MODE There are automatic shift mode and manual shift mode in the gear shift mode. Select the mode to match the use. Automatic shift mode Mode for general dozing work. The speed range is shifted down automatically when the load increases, and shifted up to the set maximum speed range when the load decreases.
  • Page 264 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR PRESET SETTING WITH SHIFT SWITCH OPERATION IN NEU- TRAL The maximum gear speed during travel (automatic shift mode) and the gear speed at start (manual shift mode) are preset by operating the shift switch in NEUTRAL. Automatic shift mode Set the maximum current gear speed.
  • Page 265 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR GEARSHIFTING OPERATION USING PRESET MODE FUNCTION Preset mode selection means the function that sets the maximum gear speed (automatic gear shift mode) or starting gear (manual gear shift mode) speed beforehand. When the joystick (steering, directional and gear shift lever) is in neutral position (N), you can change the gear shift mode by pressing UP switch (a) or DOWN switch (b).
  • Page 266 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHANGING GEAR SPEED WITH SHIFT SWITCH OPERATION WHILE TRAVELING It is possible to operate the shift switch when traveling to change the maximum set gear speed when traveling (Automatic Shift Mode) or gear speed used when traveling (Manual Shift Mode). Automatic Shift Mode Changing the maximum gear speed while the machine is trav- eling...
  • Page 267 MACHINE OPERATIONS AND CONTROLS OPERATION Manual Shift Mode Changing maximum gear speed used when traveling • When traveling forward: Possible to change gear speed used from F1 through F3 • When traveling in reverse: Possible to change gear speed used from R1 to R3 Up switch (a): Each time this is pressed, gear speed used goes up one range.

  • Page 268: Method For Switching Between Forward And Reverse

    OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR SWITCHING BETWEEN FORWARD AND REVERSE WARNING When switching the travel direction between FORWARD and REVERSE, check the safety in new direction in which the machine moves. CAUTION There is no need to stop the machine even when switching between FORWARD and REVERSE.

  • Page 269: Method For Steering Machine

    MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STEERING MACHINE WARNING • Avoid turning on a slope whenever possible, since sideways slip occurs easily. Take care particularly on soft ground or clay land. • Do not make a pivot turn. METHOD FOR NORMAL SWING OPERATION During travel, tilt joystick (steering, directional and gear shift lever) (1) in a direction you wish to turn.
  • Page 270 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR COUNTER-ROTATION TURN NOTICE • Before performing a counter-rotation turn, check the safety around the machine. • When performing a counter-rotation turn, if the load is not equal on the left and right sides, the ma- chine may perform a pivot turn, so check the ground conditions and be careful not to hit any obsta- cles.
  • Page 271 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR TURNING WHILE TRAVELING ON DOWNHILL METHOD FOR TURNING THE MACHINE GRADUALLY WHILE TRAVELING FOR- WARD When gradually turning to the left, tilt joystick (steering, direc- tional and gear shift lever) forward and tilt it to left (L) halfway. Cross steering does not occur.

  • Page 272: Recommended Working Modes For Works

    OPERATION MACHINE OPERATIONS AND CONTROLS RECOMMENDED WORKING MODES FOR WORKS FEATURES OF WORKING MODES When gear shift mode selector switch (1) is used, gear shift mode can be changed. Gear shift mode Features This mode is recommended for normal soil quality and operations, such as digging, hauling, grading, and leveling.
  • Page 273 MACHINE OPERATIONS AND CONTROLS OPERATION AA: Standard screen MM: “Mode Select” screen (1) Gear-shift mode selector switch (3) Reverse travel slow mode switch (2) Operating mode selector switch For the details of the reverse travel slow mode, see “REVERSE SLOW MODE SWITCH (3-50)”. RECOMMENDED WORKING MODES Gear shift mode Working mode...

  • Page 274: Precautions For Operation

    OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR OPERATION WATCH GAUGES If the power train oil temperature caution lamp lights up during operation, reduce the load and wait for the tem- perature to go down. PERMISSIBLE WATER DEPTH When operating in water, always keep the bottom of carrier roll- ers (1) above the surface of the water.

  • Page 275: Precautions When Operating On Slope

    MACHINE OPERATIONS AND CONTROLS OPERATION PRECAUTIONS WHEN OPERATING ON SLOPE Pay attention to fuel level If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle of the machine or the swaying of the machine. This makes the engine stop, so be careful not to let the fuel level in the fuel tank become too low.

  • Page 276: Do Not Modify Cab Glass In Any Way That Will Obstruct The View

    OPERATION MACHINE OPERATIONS AND CONTROLS DO NOT MODIFY CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW Never install anything which obstructs the view and affects the safety to the glass. Keep the glass clean and secure the safety for the work. PRECAUTIONS FOR FLOATING OPERATION If the blade is operated to FLOAT when the engine is running at low speed or when it is idling, hunting may occur.

  • Page 277: Recommended Applications

    MACHINE OPERATIONS AND CONTROLS OPERATION RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attach- ments. DOZING WORK Cut soil and sand and move them forward. When cutting a slope surface, it is more efficient to always cut from top toward bottom.
  • Page 278 OPERATION MACHINE OPERATIONS AND CONTROLS WORKS OF CUTTING INTO HARD OR FROZEN GROUND OR DITCH For digging and ditch excavation of hard or frozen ground, tilt the blade. Even hard ground can be dug effectively by a tilted or angled blade. WORKS OF FELLING TREES AND REMOVING STUMPS NOTICE Do not perform stump removal or other hard work by angling tilting the blade.

  • Page 279: Method For Adjusting Work Equipment

    MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING WORK EQUIPMENT ADJUST TENSION OF CENTER BRACE (Straight tilt dozer, straight tilt power pitch dozer, sigma dozer, and sigma power pitch dozer) When transporting the machine, remove the whole set of the work equipment. When assembling again, adjust the tension of the center brace.
  • Page 280 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING BRACE FOR USING BLADE IN STANDARD POS- TURE CAUTION Adjust the brace to a proper length. If the brace is not adjusted to a proper length, an excessive bending stress may be applied to the center pin, which may be broken.
  • Page 281 MACHINE OPERATIONS AND CONTROLS OPERATION ADJUST SHIMS IN ASSEMBLING WORK EQUIPMENT • When assembling the work equipment, if the adjustment of the play is not performed properly, excessive bending stress will be generated at all parts, and this will lead to cracks or breakage. Adjust the play in adjustment portions (1) to (4) to proper values.
  • Page 282 OPERATION MACHINE OPERATIONS AND CONTROLS ADJUST ANGLE OF BLADE EDGE WARNING It is dangerous if the work equipment moves by mistake when the angle of blade edge is adjusted. Set the work equipment in a stable condition, then stop the engine. Set the work equipment lock lever in LOCK position securely.
  • Page 283 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING ANGLE OF BLADE EDGE ON SIGMA DOZER Turn the brace with bar handle (1). • If distance between joints (B) is increased, angle (A) of the blade edge is increased. • If distance between joints (B) is decreased, angle (A) of the blade edge is decreased.
  • Page 284 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING ANGLE OF BLADE EDGE ON POWER ANGLE POW- ER TILT DOZER Remove bolts (2) (2 pieces). Remove cover (3). Insert a bar in hole (C) of rod (1) and turn rod (1). Angle (A) Distance be- of blade...
  • Page 285 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK When the maximum cutting angle (blade tilted fully forward) is changed to the minimum cutting angle (blade tilt- ed fully backward), there is resistance from the pressure stored in the angle cylinder, so the operating effort may gradually become heavier.
  • Page 286 OPERATION MACHINE OPERATIONS AND CONTROLS ADJUST TILT METHOD FOR ADJUSTING TILT OF ANGLE DOZER WARNING When adjusting the amount of tilt, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a stable condition, then stop the engine. Place the work equipment lock lever in LOCK position securely.
  • Page 287 MACHINE OPERATIONS AND CONTROLS OPERATION Tighten set bolt (1). METHOD FOR ANGLING BLADE (Angle dozers only) WARNING • When adjusting the amount of angling, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a stable condition, then stop the engine. Place the work equipment lock lever in LOCK position securely.
  • Page 288 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING TILT FOR USING BLADE IN ANGLED POSTURE (Angle dozers only) Adjust the brace length properly according to the following procedure. Return the blade to the standard posture (non-angled posture). Adjust the tilt to necessary amount. Angle the blade.

  • Page 289: Tips For Longer Undercarriage Life

    OPERATION METHOD • Use a track shoe suitable for soil condition. For selection of the shoe, consult your Komatsu distributor. • Do not let the shoe slip during operation. If the shoe starts slipping, decrease the load to prevent slipping.
  • Page 290 Frequent inspection and prompt repair will reduce repair costs. The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per- form periodical inspection and contact the Komatsu distributor in your area when machine has approached re- pairable limits and reversing limits.
  • Page 291 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR MEASURING TRACK ROLLER DIAMETER Measure the link tread (dimension C) as shown in the fig- ure. Stop the machine at a position where the link tread, at which dimension C was measured, is perfectly in contact with the roller tread.

  • Page 292: Method For Parking Machine

    OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR PARKING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Place the machine on a firm, level ground. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, place parking brake lever (4) in LOCK position and insert blocks underneath the track shoes to pre- vent the machine from moving.
  • Page 293 MACHINE OPERATIONS AND CONTROLS OPERATION Set blade control lever (5) to LOWER position (C) and low- er the blade to the ground. Return blade control lever (5) to HOLD position (B). Set ripper control lever (6) to LOWER position (c) and low- er the ripper to the ground.

  • Page 294: Method For Checking After Finishing Work

    If oil or coolant leakage or any abnormality is detected, repair it. Check AdBlue/DEF tank, pump, injector, hose, and joint for leakage. If any abnormality is found, ask your Komatsu distributor for repair. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.

  • Page 295: Lock

    MACHINE OPERATIONS AND CONTROLS OPERATION LOCK The following sections are lockable to prevent vandalism. Places that can be locked with the starting switch key. • Top cover at front of chassis (1) • Toolbox storage cover (2) • Cab door opener (3) (right and left) (Machine equipped with cab) •...
  • Page 296 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING CAP WITH LOCK PROCEDURE FOR OPENING CAP WITH LOCK Insert the key into the key slot. Make sure that you have inserted the key fully (1) before turning it. If the key is turned when only partially inserted, it may break.
  • Page 297 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP PROCEDURES FOR OPENING FUEL FILLER PORT CAP Raise lever (1) in the direction (a). Turn lever (1) in direction (c) (counterclockwise) approxi- mately 35 °. The cap stops at the stopper, and you can open it. PROCEDURES FOR CLOSING FUEL FILLER PORT CAP After turning lever (1) in the (c) direction (counterclock- wise), keep it in that position and fit the cap.
  • Page 298 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK Insert the key into the key slot. Turn the key counterclockwise and open the cover by pulling the cover handle. • Cab door opener Position (A): OPEN Position (B): CLOSE (LOCK)
  • Page 299 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING AdBlue/DEF TANK FILLER CAP COVER CAUTION • When opening or closing the AdBlue/DEF tank filler cap cover, place the machine on a level place, lower the work equipment to the ground, stop the engine, then perform the operation. •...
  • Page 300 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING AdBlue/DEF TANK FILLER PORT CAP METHOD FOR OPENING AdBlue/DEF TANK FILLER PORT CAP Open AdBlue/DEF tank filler port cover. Turn AdBlue/DEF tank filler port cap (1) counterclockwise (O) and open it. Direction (O): Open Direction (C): Close When the cap does not open easily, open AdBlue/DEF tank filler port cap by using the special tool.

  • Page 301: Handle Air Conditioner

    If any abnormality is detected in any equipment or sensor used on the air conditioner, the air conditioner system caution lamp lights up on the monitor screen. If the air conditioner system caution lamp lights up, ask your Komatsu distributor for inspection and repair. Ventilation •...

  • Page 302: Explanation Of Air Conditioner Equipment

    OPERATION HANDLE AIR CONDITIONER EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) Sunlight sensor (6) Vent selector switch (2) Display monitor (7) FRESH/RECIRC air selector switch (3) Auto switch (8) Fan switch (4) Air conditioner switch (9) Temperature control switch (5) OFF switch OFF SWITCH This switch is used for stopping the fan and air conditioner.
  • Page 303 HANDLE AIR CONDITIONER OPERATION FAN SWITCH You can adjust the air flow by using the fan switch. The air flow can be adjusted to 6 levels. Press the △ switch to increase the air flow; press the ▽ • switch to decrease the air flow. •...
  • Page 304 OPERATION HANDLE AIR CONDITIONER REMARK If the mode is set to auto mode and the temperature setting is set to 18.0 °C {64.4 °F}  or 32.0 °C {89.6 °F} , the air flow from the fan is always set to HIGH and does not change even when the temperature reaches the set value.
  • Page 305 HANDLE AIR CONDITIONER OPERATION Vent LCD display Air vent mode Remarks Foot vent ○ Foot vent ○ Not selected in auto mode Defroster vent Defroster vent ○ Not selected in auto mode AUTO SWITCH Use the auto switch for automatic selection of the air flow, vents, and air source (FRESH/RECIRC) according to the set temperature.
  • Page 306 OPERATION HANDLE AIR CONDITIONER DISPLAY MONITOR This monitor display indicates the status of temperature setting (a), air flow (b), and vents (c). When OFF switch (1) is pressed, the display of temperature setting (a) and air flow (b) goes out, and operation stops. AIR CONDITIONER SWITCH Use air conditioner switch for turning the air conditioner (cool- ing, dry heating) ON or OFF.
  • Page 307 HANDLE AIR CONDITIONER OPERATION SUNLIGHT SENSOR Sunlight sensor automatically adjusts the flow of air from the vents to match the strength of the sun's rays. In addition, it au- tomatically detects changes in the temperature inside the cab caused by changes in the strength of the sun's rays beforehand and automatically adjusts the temperature.

  • Page 308: Method For Operating Air Conditioner

    OPERATION HANDLE AIR CONDITIONER METHOD FOR OPERATING AIR CONDITIONER The air conditioner can be operated automatically or manually. Select the method of operation as desired. METHOD FOR AUTOMATIC OPERATION Turn auto switch (1) ON. Set temperature (a) and air flow (b) are displayed. Use temperature control switch (2) to set to the desired temperature.
  • Page 309 HANDLE AIR CONDITIONER OPERATION REMARK When vent display monitor (c) displays (d) or (e), and engine coolant temperature is low, the air flow is automatically limited to prevent cold air from blowing out. METHOD FOR STOPPING AUTOMATIC OPERATION Press OFF switch (1). The air conditioner stops.
  • Page 310 OPERATION HANDLE AIR CONDITIONER METHOD FOR MANUAL OPERATION Press fan switch (1) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed. Turn air conditioner switch (2) ON. Press temperature control switch (3) to adjust the tempera- ture in the cab.
  • Page 311 HANDLE AIR CONDITIONER OPERATION Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the monitor changes according to the selection. Press FRESH/RECIRC selector switch (5) and select recir- culation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH).
  • Page 312 OPERATION HANDLE AIR CONDITIONER METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. Press fan switch (1) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed.
  • Page 313 HANDLE AIR CONDITIONER OPERATION Turn air conditioner switch (3) ON. Adjust fan switch (1), temperature control switch (4) and FRESH/RECIRC selector switch (5) to the desired posi- tions. 3-258...
  • Page 314 OPERATION HANDLE AIR CONDITIONER METHOD FOR OPERATING DEFROSTER Press fan switch (1) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed. Press vent selector switch (2) and set the vent display on the display monitor to (f) or (g) as shown in the figure.
  • Page 315 HANDLE AIR CONDITIONER OPERATION Press FRESH/RECIRC selector switch (3) and set it to FRESH mode. Press temperature control switch (4) and set temperature on the monitor to “32.0” of maximum heating. Adjust the vents so that the air blows onto the window glass.

  • Page 316: Handling Radio

    OPERATION HANDLING RADIO HANDLING RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them. •...
  • Page 317 HANDLING RADIO OPERATION PRESET BUTTON If you register desired stations to the preset button beforehand, you can select each station by touching this but- ton once. It is possible to preset 6 stations each for both AM and FM. For the presetting method, see “METHOD FOR CONTROLLING RADIO (3-264)”. DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display.
  • Page 318 OPERATION HANDLING RADIO NOTICE • A stereo miniature plug can be connected. Read the instruction manual of the equipment to connect carefully. • As a power source for the equipment to connect, use the battery attached to that equipment. If you use an electric power supply installed to the machine, the noise may occur. •...

  • Page 319: Method For Controlling Radio

    HANDLING RADIO OPERATION METHOD FOR CONTROLLING RADIO METHOD FOR ADJUSTING FREQUENCY Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency. Press the △ button, and the frequency increases; • press the ▽...
  • Page 320 OPERATION HANDLING RADIO METHOD FOR REGISTERING PRESET Hold down one of 1 to 6 of preset button (1) while listening to the radio. The currently received frequency is registered to the preset number corresponding to the pressed button. “Example” While a frequency is displayed, keep pressing button 1 of preset button (1), and the preset number “P-1” is dis- played.

  • Page 321: Antenna

    HANDLING RADIO OPERATION METHOD FOR ADJUSTING CLOCK Press display selector button (1) to display the clock. Hold down display selector button (1) to flash the “HOUR” display portion. You can adjust the hour. Press tuning/time adjustment button (2) to adjust the hour. If you press △...

  • Page 322: Transportation

    OPERATION TRANSPORTATION TRANSPORTATION TRAVEL ON ROAD When traveling on paved roads, use flat shoes to protect their surface. Even when traveling a short distance, always place boards to protect the road surface. Note that the asphalt road becomes soft in summer. PRECAUTIONS FOR TRANSPORTING MACHINE When transporting the machine, observe all related laws and regulations, and be careful to assure safety.

  • Page 323: Loading And Unloading With Trailer

    TRANSPORTATION OPERATION LOADING AND UNLOADING WITH TRAILER WARNING • Since loading and unloading of the machine is dangerous, be extremely careful. • When loading or unloading the machine, lower the engine speed, set the speed range to the 1st, and operate slowly.
  • Page 324 OPERATION TRANSPORTATION Set the parking brake lever in FREE position (F). Use the 1st gear speed and run the engine at low idle. Set the travel direction toward the ramps and drive slowly. The center of gravity of the machine shifts suddenly at the joint between the ramps and the trailer, and the machine is unbalanced and becomes unstable.
  • Page 325 TRANSPORTATION OPERATION METHOD FOR SECURING MACHINE NOTICE Be sure to lower the car radio antenna to the stow position. After loading the machine onto a trailer, secure the machine as follows. Lower the work equipment slowly. (When transporting with work equipment installed) Set the work equipment lock lever securely to LOCK posi- tion (L).
  • Page 326 OPERATION TRANSPORTATION PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm and level ground. Park a trailer on a firm and level ground. Maintain a safe distance from the road shoulder Apply the brake of the trailer securely. Set chocks (1) to the tires to secure the trailer.

  • Page 327: Method For Lifting Machine

    This method of lifting applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. For the weight, see “SPECIFICATIONS (5-2)”.
  • Page 328 OPERATION TRANSPORTATION For machine equipped with ripper • Hang the front wire ropes to each cylinder support (1) on the right and left sides. • Fit the wire ropes at the center to both left and the right pivot shafts (2). •...

  • Page 329: Cold Weather Operation

    When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
  • Page 330 OPERATION COLD WEATHER OPERATION BATTERY WARNING • Battery generates flammable gas. Never bring any open flame near fuel. • Battery electrolyte is dangerous object. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor. •...

  • Page 331: Precautions After Daily Work Completion

    Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “RECOM- MENDED FUEL, COOLANT, AND LUBRICANT (7-6)”. • If the machine is parked for long time in the cold weather condition, quality of AdBlue/DEF may be affected by repeated freeze, ask your Komatsu distributor to inspect. 3-276...

  • Page 332: Precautions For Long-Term Storage

    OPERATION PRECAUTIONS FOR LONG-TERM STORAGE PRECAUTIONS FOR LONG-TERM STORAGE PREPARATION FOR LONG-TERM STORAGE When putting the machine in long-term storage (more than one month), store it as follows. • Clean and wash all parts of the machine and store it indoors. If the machine has to be stored outdoors, place it on a level ground and cover it with tarpaulins.

  • Page 333: Starting Machine After Long-Term Storage

    If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If AdBlue/DEF is kept in AdBlue/DEF tank for more than 1 year, ask your Komatsu distributor for replace- ment. Dispose of drained AdBlue/DEF according to the local regulations and rules.

  • Page 334: Troubles And Actions

    OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS ACTIONS WHEN RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel until the fuel level caution lamp on the ma- chine monitor goes out, then bleed the air from the fuel system before starting the engine. METHOD FOR BLEEDING AIR FROM FUEL SYSTEM Insert the key into the starting switch and turn it to ON po- sition (B).

  • Page 335: Precautions For Towing Machine

    If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic sys- tem, the brake works and the machine cannot move. To move the machine in this case, the oil pressure in the brake circuit must be heightened to the specified level with a special device. Contact your Komatsu dis- tributor.

  • Page 336: Precautions For Discharged Battery

    OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
  • Page 337 TROUBLES AND ACTIONS OPERATION METHOD FOR REMOVING AND INSTALLING BATTERY Open the battery inspection cover. Turn the battery disconnect switch to OFF position (O). Loosen the terminal nut and disconnect the wiring from the battery. Before removing battery, remove the ground cable (nor- mally connected to the negative (-) terminal).
  • Page 338 OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, it is dangerous that the battery may explode. Al- ways follow the instructions in “PRECAUTIONS FOR DIS- CHARGED BATTERY (3-281)” and the instruction manual accompanying the charger, and observe the following.
  • Page 339 TROUBLES AND ACTIONS OPERATION START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
  • Page 340 OPERATION TROUBLES AND ACTIONS PROCEDURE FOR CONNECTING JUMPER CABLE Turn the starting switch and battery disconnect switch of the failed machine, and the starting switch of the nor- mal machine to OFF position. Connect the clip of jumper cable (A) to the positive (+) ter- minal of battery (C) on the failed machine.

  • Page 341: Other Trouble

    PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
  • Page 342 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Outside of electrical intake air heater Defective wiring Check, repair. (*) is not warm when touched with hand. Wire breakage in electrical intake air Replace. (*) heater Defective operation of heater relay Check, repair heater relay.
  • Page 343 PHENOMENA AND ACTIONS FOR CHASSIS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
  • Page 344 TROUBLES AND ACTIONS PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • As for the corrective actions indicated with (*) in the remedy column, always contact your Komatsu distribu- tor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
  • Page 345 AdBlue/DEF level caution lamp is dis- Lowering of AdBlue/DEF level Add AdBlue/DEF. played on monitor. Action level or caution lamp is dis- Contact your Komatsu distributor. played on monitor. Alarm buzzer sounds. Contact your Komatsu distributor. Engine suddenly lost power.
  • Page 346 (3) for the point of contact is displayed in the message column at the bottom of the screen. REMARK If no point of contact telephone number is registered, no tele- phone number is displayed. Ask your Komatsu distributor for the telephone number regis- tration if necessary. 3-291...

  • Page 348: Maintenance

    MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.

  • Page 349: Precautions For Maintenance

    Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.

  • Page 350: Precautions For Scr Assembly

    MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR SCR ASSEMBLY Be careful for the high temperature parts when performing inspection and maintenance. Even after the engine stops the parts around SCR device may be at high temperature. DUSTY JOBSITES When working at dusty jobsites, observe the following. •...

  • Page 351: Checks After Inspection And Maintenance

    PRECAUTIONS FOR MAINTENANCE MAINTENANCE CHECKS AFTER INSPECTION AND MAINTENANCE If you forget to perform the inspection and maintenance, unexpected problems may occur, and this may lead to personal injury. Always observe the following. Checks after operation (with engine stopped) • Have any inspection and maintenance points been forgotten? •...

  • Page 352: Outline Of Maintenance

    Oil remaining in the piping and cylinders may be mixed in. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the en- gine such as deteriorated oil may reduce lubricating function, and it may cause failure, shortening of the machine life, lowering of performance and increase of fuel consumption.
  • Page 353 (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
  • Page 354 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
  • Page 355 Make sure that the oil is well mixed before sampling. • Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor.
  • Page 356 • When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, consult your Komatsu distributor. • Do not open packages of spare filters until just before they are to be used.

  • Page 357: Handle Electrical Components

    Never install any electrical components other than those specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. •...

  • Page 358: Handle Hydraulic Components

    MAINTENANCE OUTLINE OF MAINTENANCE HANDLE HYDRAULIC COMPONENTS • The hydraulic system is at high temperature during and just after operation. In addition, high pressure is applied to the hydraulic system, thus pay attention to the following matters when performing inspection and maintenance of it.

  • Page 359: Standard Tightening Torque For Bolts And Nuts

    Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
  • Page 360 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Tighten the hoses to the torque shown in the table. Width Tightening torque acros Nominal - No. of Target value Allowable range s flats threads "a" "b"  Nm  kgm lbft  Nm  kgm lbft (mm) 9/16-18UNF...

  • Page 361: Maintenance Schedule

    MAINTENANCE SCHEDULE MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE TABLE WHEN REQUIRED ............................4-16 METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER .......... 4-16 METHOD FOR CLEANING INSIDE OF COOLING SYSTEM ..............4-21 METHOD FOR CHECKING AND ADJUSTING TRACK TENSION ............4-24 METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE BOLTS ......
  • Page 362 MAINTENANCE MAINTENANCE SCHEDULE TABLE METHOD FOR CHANGING OIL IN DAMPER CASE ................4-81 METHOD FOR CHANGING OIL IN HYDRAULIC TANK, REPLACING HYDRAULIC OIL FILTER ELEMENT, AND CLEANING HYDRAULIC TANK STRAINER ................4-82 METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA- TOR (FOR CONTROL CIRCUIT) ......................

  • Page 363: Maintenance Procedure

    MAINTENANCE PROCEDURE MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING • If inspection, cleaning, or maintenance is performed while the engine is running, dust enters into the engine and damages it. Be sure to stop the engine before performing these works. •...
  • Page 364 MAINTENANCE MAINTENANCE PROCEDURE • When the inside yellow piston of dust indicator (1) laps over the peripheral red zone (A) METHOD FOR CLEANING AND REPLACING OUTER ELEMENT Open the engine side cover on the left side of the machine. Remove clips (2) (3 pieces) and remove cover (3). NOTICE •...
  • Page 365 MAINTENANCE PROCEDURE MAINTENANCE Blow dry compressed air (Max. 0.2 MPa {2.1 kg/cm 30.0 PSI}) from the inside of the outer element along the pleats. Blow dry compressed air from the outside of the outer ele- ment along the pleats. Blow dry compressed air again from the inside of the outer element along the pleats.
  • Page 366 MAINTENANCE MAINTENANCE PROCEDURE If the air cleaner clogging caution lamp lights up soon after cleaning or the yellow piston of dust indicator (1) laps over the red zone (7.5 kPa {0.08 kg/cm , 1.1 PSI}), even if the outer element has not been cleaned up to 6 times, replace both the inner and outer elements.
  • Page 367 MAINTENANCE PROCEDURE MAINTENANCE Push the button of dust indicator (1). The yellow piston returns. REMARK Immediately after a new element has been installed, the yellow piston of the dust indicator may go to the 2nd posi- tion, but this does not indicate any abnormality. 10.

  • Page 368: Method For Cleaning Inside Of Cooling System

    NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
  • Page 369 When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
  • Page 370 MAINTENANCE MAINTENANCE PROCEDURE 18. Add Non-Amine Engine Coolant (AF-NAC) to the middle between FULL and LOW. 19. Stop the engine. 20. After 3 minutes, add Non-Amine Engine Coolant (AF-NAC) up to the mouth of the coolant filler port. 21. Tighten radiator cap (1). 22.

  • Page 371: Method For Checking And Adjusting Track Tension

    Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened by the above pro- cedure, ask your Komatsu distributor for repair. METHOD FOR INCREASING TRACK TENSION NOTICE •...
  • Page 372 METHOD FOR DECREASING TRACK TENSION WARNING It is extremely dangerous to release the grease by any method other than the following procedure. If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs. NOTICE • The safety indicator is stuck to the back of cover (3). Take care not to damage the safety indicator.

  • Page 373: Method For Checking Looseness And Tightening Track Shoe Bolts

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE BOLTS NOTICE If the machine is used with track shoe bolts loose, they will break. Tighten any loose bolt immediately. Check for looseness of track shoe bolt (1). If any bolt is loose, retighten it. METHOD FOR RETIGHTENING TRACK SHOE BOLT Tighten the track shoe bolts in the order shown in the fig- ure.

  • Page 374: Method For Checking Idler Oil Level

    When oil oozes out through thread portion You do not need to add oil. • When no oil oozes out through thread portion The oil is insufficient. Ask your Komatsu distributor for adding. After checking, tighten plug (4). Install guide plate (2) and shim (3).

  • Page 375: Method For Adjusting Idler Clearance

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR ADJUSTING IDLER CLEARANCE Since the idlers are forced to move forward and backward by an external force, guide plates will be worn out. Wear of guide plates will cause the vibration of idlers from side to side or inclination of the idlers, and running off of track links from the idlers or unevenly worn idler and links may result.

  • Page 376: Method For Lubricating Universal Joint

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR LUBRICATING UNIVERSAL JOINT WARNING The undercover is a heavy part (22 kg (48.5 lb)). Do not open or close the cover just under it. When removing bolts(2), perform the work from the rear of the cover so that you can easily get out of the way.

  • Page 377: Method For Inverting And Replacing Cutting Edge And End Bit

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR INVERTING AND REPLACING CUTTING EDGE AND END BIT WARNING It is dangerous if the work equipment moves by mistake when the cutting edge and end bit are turned 180 ° or replaced. Set the work equipment in a stable condition, place the work equipment lock lever in LOCK position, then stop the engine.
  • Page 378 MAINTENANCE MAINTENANCE PROCEDURE Loosen nut (1) and remove bolt (2). Remove the cutting edge and end bit. Clean the mounting face. Turn the cutting edge and end bit 180 degrees or replace them with new ones. Install the cutting edge and end bit, and tighten them light- If nut (1) and bolt (2) are damaged, replace them as well.

  • Page 379: Clean And Check Radiator Fins And Oil Cooler Fins

    MAINTENANCE PROCEDURE MAINTENANCE CLEAN AND CHECK RADIATOR FINS AND OIL COOLER FINS If there is any mud or dirt stuck to the radiator or oil cooler, clean them. Check the rubber hoses. If they are cracked or fragile, replace them. Also, check the hose clamp for looseness. METHOD FOR CLEANING FIN BY ROTATING HYDRAULIC DRIVE FAN IN RE- VERSE NOTICE...
  • Page 380 MAINTENANCE MAINTENANCE PROCEDURE REMARK Even if Fan Reverse Mode is set while the engine is run- ning, the fan rotation direction is not reversed. The screen in the figure is displayed to inform the operator that the direction of rotation of the fan has not been changed.
  • Page 381 MAINTENANCE PROCEDURE MAINTENANCE CLEAN WITH COMPRESSED AIR WARNING • If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the compressed air, high-pressure water, or steam, there is a danger of personal injury. Always wear protective equipment such as protective eyeglasses and dust mask.

  • Page 382: Method For Cleaning Hydraulic Tank Breather

    MAINTENANCE MAINTENANCE PROCEDURE Clean the space between the front surface of the hydraulic oil cooler and the rear surface of the radiator. Remove mounting bolt (4). Remove cover (3). Use compressed air to blow off the mud, dirt, or leaves clogging the space. METHOD FOR CLEANING HYDRAULIC TANK BREATHER At the check and maintenance, if the breather is dirty, clean it.

  • Page 383: Method For Cleaning Fuel Tank Breather

    METHOD FOR CHECKING AND ADJUSTING ALTERNATOR AND AIR CONDI- TIONER COMPRESSOR BELT TENSION For replacement of the alternator and air conditioner compressor drive belt, ask your Komatsu distributor. METHOD FOR REPLACING DOOR DAMPER Measure groove depth (A) of door damper rubber (1).

  • Page 384: Method For Lubricating Door Hinge

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR LUBRICATING DOOR HINGE Perform this when the door creaks when it opens or closes. Supply spray lubricant through the bushing slit of the hinge. If the bushing is worn, replace the hinge. METHOD FOR CHECKING DOOR LATCH Keep the door open.

  • Page 385: Method For Checking Window Washer Fluid Level, Adding Fluid

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID Perform this check when no window washer fluid comes out. Open the battery inspection cover at the rear of the machine. Check the fluid level in window washer tank (1). If the fluid level is low, remove cap (2) and add window washer fluid for automobile through the filler port.

  • Page 386: Method For Replacing Wiper Blade

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING WIPER BLADE If the blade is damaged, it will not wipe the window clean, so replace the blade. METHOD FOR REPLACING FRONT WIPER The front wiper is hooked at portion (A). Move the blade in the direction of the arrow. The blade comes off.
  • Page 387 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING DOOR WIPER The front wiper is hooked at portion (A). Move the blade in the direction of the arrow. The blade comes off. Install the new blade and hook it securely. 4-40...

  • Page 388: Method For Checking And Maintenance Air Conditioner

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR DRIVE BELT TEN- SION If the driving belt slackens, it is likely to slip, lowering the cooling efficiency. The air conditioner compressor drive belt is on the left side of the machine.
  • Page 389 (C) Colorless, transparent: No refrigerant REMARK If bubbles are seen, the gas is insufficient. Ask your Komatsu distributor for adding. If the air conditioner is operated with the refrigerant gas level low, it will cause damage to the compressor. New Freon R134a is used as the refrigerant.

  • Page 390: Method For Bleeding Air From Hydraulic Circuit

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT Since the engine must be started and the blade must be operated, see OPERATION. For the starting procedure of the engine, see “METHOD FOR STARTING ENGINE (3-193)”. NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing.

  • Page 391: Method For Installing Trunnion Cap

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR INSTALLING TRUNNION CAP Lower the work equipment to the ground. Set the work equipment lock lever to LOCK position. Stop the engine. Install the shims. (Top, bottom: 2 places) (A) Standard number of shims: Thickness 1 mm (0.039 in) x 10 pieces Tighten bolts (1) alternately until they reach the specified torque.

  • Page 392: Adjust Shims, Adjust Tension At Work Equipment Links

    MAINTENANCE MAINTENANCE PROCEDURE ADJUST SHIMS, ADJUST TENSION AT WORK EQUIPMENT LINKS When assembling the work equipment, perform adjustment as follows. Check the play of the links periodically and perform adjustment. When disassembling the machine for transportation, be careful not to lose the shims. NEED FOR ADJUSTING WORK EQUIPMENT LINKS CAUTION If the clearances at each ball joint of the work equipment and the tension of the center brace are not...
  • Page 393 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR ADJUSTING LOCATIONS AND METHOD FOR ADJUSTING WORK EQUIPMENT LINKS WARNING It is dangerous if the work equipment moves by mistake when it is being adjusted. Park the machine on a level ground, set the work equipment in a stable state, and stop the engine. Se- curely set the parking brake lever and work equipment lock lever in LOCK position.
  • Page 394 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR ADJUSTING SHIMS AT TILT BRACE, TILT CYLINDER HEAD, AND PITCH CYLINDER HEAD • Correct value for play at ball joint: 0.2 to 0.7 mm (0.008 to 0.028 in) • Standard shim thickness: 5 mm (0.197 in) Adjust the play in the ball joint to the correct value, according to the following procedure. Remove bolts (1), and remove cap (2).
  • Page 395 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR ADJUSTING SHIMS AT LIFT CYLINDER HEAD • Correct value for play at ball joint: 0.2 to 0.7 mm (0.008 to 0.028 in) • Standard shim thickness: 4 mm (0.157 in) Adjust the play in the ball joint to the correct value, according to the following procedure. Remove bolts (1), and remove cap (2).
  • Page 396 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR ADJUSTING SHIMS AT CENTER BRACE • Correct value for play at ball joint: 0.2 to 0.7 mm (0.008 to 0.028 in) • Standard shim thickness: 5 mm (0.197 in) Adjust the play in the ball joint to the correct value, according to the following procedure. Remove bolts (1), and remove cap (2).
  • Page 397 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR ADJUSTING SHIMS AT TRUNNION • Correct value for play at ball joint: 0.2 to 1.2 mm (0.008 to 0.047 in) • Standard shim thickness: 10 mm (0.394 in) Adjust the play in the ball joint to the correct value, according to the following procedure. Remove bolts (1), and remove cap (2).
  • Page 398 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR ADJUSTING TENSION OF CENTER BRACE (Straight tilt dozer) (Straight tilt power pitch dozer) (Sigma dozer) (Sigma power pitch dozer) When transporting the machine, remove the whole set of the work equipment. When installing again, adjust the tension of the center brace.

  • Page 399: Checks Before Starting

    MAINTENANCE PROCEDURE MAINTENANCE CHECKS BEFORE STARTING For the following items, see OPERATION, “METHOD FOR CHECKING BEFORE STARTING (3-159)”. • Method for draining water and sediment from fuel tank • Method for checking water separator, draining water and sediment • Method for checking oil level in hydraulic tank, adding oil •...

  • Page 400: Every 50 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 50 HOURS MAINTENANCE METHOD FOR LUBRICATING POWER ANGLE POWER TILT DOZER Lower the blade to the ground and stop the engine. By using a grease pump, pump in grease through the grease fittings. After greasing, wipe off any old grease that is pushed out. Greasing point (1) Pitch rod pin (2 places) (3) Center ball (1 place)

  • Page 401: Every 250 Hours Maintenance

    MAINTENANCE PROCEDURE MAINTENANCE EVERY 250 HOURS MAINTENANCE Maintenance for every 50 hours service should be performed at the same time. METHOD FOR LUBRICATING Lower the blade to the ground and stop the engine. When lubricating the lift cylinder support shaft, lower the blade to raise the idler 1 to 2 cm (0.4 to 0.8 in) from the ground, then stop the engine.
  • Page 402 MAINTENANCE MAINTENANCE PROCEDURE Lubricating points of angle dozer (1) Lift cylinder support yoke (4 places) (2) Lift cylinder support shaft (2 places) (3) Lift cylinder ball joint (2 places) (4) Tilt brace ball joint (1 places) (5) Tilt brace thread (2 places) Lubricating points of power angle power tilt dozer (1) Lift cylinder support yoke (4 places) (2) Lift cylinder support shaft (2 places)

  • Page 403: Method For Lubricating Equalizer Bar Side Pin

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR LUBRICATING EQUALIZER BAR SIDE PIN (1 place each on right and left sides) Remove all soil and sand from the top of the track frame and top of the cover. Clean the grease fitting shown by arrow. Supply grease by using a grease pump.

  • Page 404: Method For Checking Oil Level In Final Drive Case, Adding Oil

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL WARNING Immediately after the engine is stopped, parts and oil are still very hot. Accordingly, wait until they have cooled down before starting the work. Stop the machine so that drain plug (1) is directly at the bottom.

  • Page 405: Method For Checking Battery Electrolyte Level

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL WARNING • Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. If you do so, it will reduce the service life of the battery. In addition, it may cause an explosion. •...
  • Page 406 If purified water is added to above U.L. line, use a syringe to lower the level to U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, con- sult your Komatsu distributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO...

  • Page 407: Method For Checking And Cleaning Additional Fuel Strainer

    (4). Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL ON INDICATOR ETC If it is possible to use an indicator to check the electrolyte level, follow the instructions given.

  • Page 408: Method For Checking Brake Performance

    MAINTENANCE PROCEDURE METHOD FOR CHECKING BRAKE PERFORMANCE WARNING If the machine moves off during the following operation, ask your Komatsu distributor for repairs imme- diately. NOTICE Never set the joystick (steering, directional and gear shift lever) to the 1st gear speed. This will cause damage to the machine.

  • Page 409: Every 500 Hours Maintenance

    Check the drained oil. If there are excessive metal particles or foreign material, contact your Komatsu distributor. Tighten drain plug (P). Open the engine side cover on the right side of the ma- chine.
  • Page 410 MAINTENANCE MAINTENANCE PROCEDURE Turn engine oil filter cartridge (5) counterclockwise by us- ing the filter wrench, and remove it. Clean the filter head. 10. Fill the new filter cartridge with clean oil, coat the packing face and thread with oil (or coat thinly with grease), then install the filter cartridge.

  • Page 411: Method For Replacing Fuel Prefilter Cartridge

    The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
  • Page 412 MAINTENANCE MAINTENANCE PROCEDURE Tightening torque of transparent cup: 10 Nm {1.0 kgm, 7.2 lbft} REMARK If the transparent cup is fastened too much, the O-ring will be damaged and this leads to leakage of fuel. If it is too loose, fuel will also leak from gaps of the O-ring. Therefore, be sure to observe the tightening angle. 11.
  • Page 413 MAINTENANCE PROCEDURE MAINTENANCE Insert the key into the starting switch and turn it to ON position (B). The fuel feed pump is actuated. Hold the key in ON position (B) for 30 seconds. Then, return the key to OFF position (A) and hold it there for 10 seconds.

  • Page 414: Method For Replacing Element On Power Train Oil Filter

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING ELEMENT ON POWER TRAIN OIL FILTER WARNING Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. Prepare a filter wrench and a container to catch the oil.

  • Page 415: Method For Replacing Air Conditioner Fresh/Recirc Filters

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC FILTERS REMARK Since the filtering ability of the filters decreases as they are aged, replace them every 500 operating hours or every year. METHOD FOR REPLACING RECIRCULATION AIR FILTER Remove knob (1) at the rear left in the cab, and remove bracket (2).
  • Page 416 MAINTENANCE MAINTENANCE PROCEDURE Remove fresh air filter (6). Remove soil and sand from the sealing surface of fresh air filter covers (5) and inside of the filter cases. Install the new fresh air filter. REMARK The fresh air filter has thin side (S) and thick side (L). Install the fresh air filter with thick side (L) down.

  • Page 417: Every 1000 Hours Maintenance

    MAINTENANCE PROCEDURE MAINTENANCE EVERY 1000 HOURS MAINTENANCE Maintenance for every 50, 250 and 500 hours should be performed at the same time. METHOD FOR CHANGING OIL IN POWER TRAIN CASE, CLEAN POWER TRAIN PUMP STRAINER AND SCAVENGING PUMP STRAINER WARNING •...
  • Page 418 MAINTENANCE MAINTENANCE PROCEDURE Lower and open the cover gradually. (A) Front of machine (B) Dangerous place Place the oil container to catch oil under cover (5). Loosen mounting bolts (4) of the power train pump strain- er, and remove cover (5). Take out spring (6) and then take out strainer (7).

  • Page 419: Method For Changing Oil In Final Drive Case

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHANGING OIL IN FINAL DRIVE CASE WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Accordingly, wait until they have cooled down before starting the work. •...

  • Page 420: Method For Replacing Fuel Main Filter Cartridge

    The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
  • Page 421 MAINTENANCE PROCEDURE MAINTENANCE Place a container under filter cartridge (4) to catch the fuel. Turn filter cartridge (4) counterclockwise by using the filter wrench, and remove it. NOTICE • Do not fill the new filter cartridge with fuel. • Remove cap (B) at center and install the filter car- tridge.
  • Page 422 MAINTENANCE MAINTENANCE PROCEDURE Then, return the key to OFF position (A) and hold it there for 10 seconds. Repeat above steps 2) to 4) 4 times. Turn the starting switch key to START position (C) and start the engine. 12. Check the filter seal surface for fuel leakage. If the leakage is noticed, check the filter cartridge for its tightening condition.

  • Page 423: Method For Replacing Fuel Tank Breather Element

    For replacement of the hydraulic tank breather element, see “METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT (4-77)”. METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. 4-76...

  • Page 424: Method For Cleaning Power Train Case Breather

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING POWER TRAIN CASE BREATHER Remove bolts (1) of step. Remove step (2). Remove bolts (3). Remove cover (4). Remove breather (5). Rinse breather (5) in clean diesel fuel or flushing oil, and remove dirt from inside. METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT NOTICE Note that the fuel tank breather and hydraulic tank breather have different part numbers.

  • Page 425: Method For Replacing Adblue/Def Tank Breather Element

    If the machine is operated without AdBlue/DEF tank breather element attached, or with the element other than Komatsu genuine parts, foreign materials may enter into AdBlue/DEF pump and AdBlue/DEF injector which will cause failure of the machine. Never operate the machine without AdBlue/DEF tank breather element attached, nor use the element other than Komatsu genuine parts.

  • Page 426: Method For Checking Oil Level In Damper Case And Adding Oil

    MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING OIL LEVEL IN DAMPER CASE AND ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury. Ac- cordingly, wait until they have cooled down before starting the work.

  • Page 427: Method For Checking For Loose Rops Mount Bolts

    • When any bolt is loose Tighten the bolt. Tightening torque: 245 to 309 Nm {25 to 31.5 kgm, 180.8 to 227.8 lbft} • When any bolt is damaged Replace the bolt with a Komatsu genuine part. 4-80...

  • Page 428: Every 2000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 50, 250, 500 and 1000 hours service should be performed at the same time. METHOD FOR CHANGING OIL IN DAMPER CASE WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.

  • Page 429: Method For Changing Oil In Hydraulic Tank, Replacing Hydraulic Oil Filter Element, And Cleaning Hydraulic Tank Strainer

    MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHANGING OIL IN HYDRAULIC TANK, REPLACING HYDRAULIC OIL FILTER ELEMENT, AND CLEANING HYDRAULIC TANK STRAINER WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.

  • Page 430: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tor (For Control Circuit)

    • Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
  • Page 431 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING FUNCTION OF ACCUMULATOR CAUTION When operating the blade control lever to lower the blade, check the safety around the machine. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
  • Page 432 Check that the work equipment goes down to the ground under its own weight. In the following cases, the gas charge pressure of the accumulator has gone down. Contact your Komatsu dis- tributor. • Work equipment does not go down •...

  • Page 433: Method For Checking Alternator

    Ask your Komatsu distributor to have the alternator checked. If the engine is started frequently, have this inspection performed every 1000 hours. METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. 4-86...

  • Page 434: Method For Replacing Kccv Filter Element

    Wait until all of parts cool down before starting the work. NOTICE • Komatsu recommends using Komatsu genuine parts for replacement parts. • If the engine is operated without the filter element, the turbocharger and aftercooler become dirty and their performance will lower and that can cause engine problems such as overrun caused by suction of oil.
  • Page 435 MAINTENANCE PROCEDURE MAINTENANCE After ring (3) comes off, remove case (4) from body (2) and remove element (5). There may be oil accumulated or sticking in the case and element. Take care not to spill the oil when replacing the element.
  • Page 436 MAINTENANCE MAINTENANCE PROCEDURE Align the position of ◇ mark (8) on the case with that of ◇ mark (11) of the filter body label, then install the case to the filter body. The element can be installed only when its claw (12) and claw (13) of the case are correctly inserted in groove (14) of the body.

  • Page 437: Method For Replacing Adblue/Def Filter

    Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without AdBlue/DEF filter attached, or with the filter other than Komatsu genuine parts, foreign materials may enter into AdBlue/DEF pump and AdBlue/DEF injector which will cause failure of the machine. Never operate the machine without AdBlue/DEF filter attached, nor use the filter other than Komatsu genuine parts.
  • Page 438 MAINTENANCE MAINTENANCE PROCEDURE Turn cap (4) of filter removal tool (3) and remove it. Check the installation of spacer (5). Insert filter removal tool (3) into the bottom of the AdBlue/DEF pump and thrust in with hand. Check that filter removal tool (3) is fully inserted to the end. Insert the filter removal tool to the end where you cannot thrust it in any further.
  • Page 439 MAINTENANCE PROCEDURE MAINTENANCE Pull filter (6) up while pushing in the tip of filter removal tool (3), and remove it. Return the removed spacer (5) to filter removal tool (3), and keep them. 10. Insert a new filter and a new equalizing element into the bottom of AdBlue/DEF pump, and lightly tighten them with hand.

  • Page 440: Every 4000 Hours Maintenance

    MAINTENANCE MAINTENANCE PROCEDURE EVERY 4000 HOURS MAINTENANCE Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be performed at the same time. REPLACE DEFINED LIFE PARTS These parts change in material, wear, and deteriorate as they are aged. Replace them every 2 years or every 4000 hours, whichever comes sooner.

  • Page 441: Method For Checking Water Pump

    • Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. NOTICE If the nitrogen gas charge pressure in accumulator (1) is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.

  • Page 442: Method For Checking For Looseness Of Engine High-Pressure Piping Clamp, Hard- Ening Of Rubber

    Check clamp (1) visually and with your fingers that there are no loose bolts or hardening of the rubber. If there is any loose bolt or hardened rubber, ask your Komatsu distributor for replacement. 4-95...
  • Page 443 Check the fuel spray prevention caps visually or with a finger to see if any of them has slipped off, or the rubber portion is hardened. If there is any loose bolt or hardened rubber, ask your Komatsu distributor for replacement. 4-96...

  • Page 444: Every 4500 Hours Maintenance

    Contact your Komatsu distributor for cleaning of the KDPF. METHOD FOR CLEANING AdBlue/DEF TANK Ask your Komatsu distributor for cleaning of the AdBlue/DEF tank. METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION Ask your Komatsu distributor for cleaning of the mounting portion of the AdBlue/DEF tank. 4-97...

  • Page 445: Every 8000 Hours Maintenance

    EVERY 8000 HOURS MAINTENANCE Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be performed at the same time. METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor for replacement of the fuel spray prevention caps. 4-98...

  • Page 446: Every 9000 Hours Maintenance

    MAINTENANCE PROCEDURE EVERY 9000 HOURS MAINTENANCE Maintenance for every 50, 250, 500, 1000 and 4500 hours service should be performed at the same time. METHOD FOR REPLACING AdBlue/DEF HOSE Ask your Komatsu distributor for replacement of the AdBlue/DEF hose. 4-99...

  • Page 448: Specifications

    SPECIFICATIONS...

  • Page 449: D65Ex-18 Specifications

    20070 (44254) 19740 (43527) 21770 (48003) Machine weight  kg( lb) [20470 (45136)] [20140 (44409)] [22180 (48907)] Engine model Komatsu SAA6D114E-6 diesel engine SAE J1995 164 {220}/ 1950 {1950} Rated (Gross)  kW{ HP}/ horse-  min { rpm} ISO 9249/ SAE J1349 power...

  • Page 450: D65Px-18 Specifications

    Power angle power tilt Straight tilt dozer dozer 21550 (47518) 22420 (49436) Machine weight  kg ( lb) [22020 (48554)] [22880 (50450)] Engine model Komatsu SAA6D114E-6 diesel engine SAE J1995 164 {220}/ 1950 {1950} Rated (Gross)  kW{ HP}/ horse-  min { rpm} ISO 9249 /SAE J1349...

  • Page 451: D65Wx-18 Specifications

    Power angle power tilt SIGMA dozer dozer 20920 (46129) 22670 (49987) Machine weight  kg ( lb) [21360 (47099)] [23110 (50958)] Engine model Komatsu SAA6D114E-6 diesel engine SAE J1995 164 {220}/ 1950 {1950} Rated (Gross)  kW{ HP}/ horsepow-  min { rpm} ISO 9249 /SAE J1349...

  • Page 452: Attachments And Options

    ATTACHMENTS AND OPTIONS Please read and make sure that you understand the SAFETY section before reading this section.

  • Page 453: General Precautions

    GENERAL PRECAUTIONS PRECAUTIONS FOR SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distrib- utor first.

  • Page 454: Handle Hydraulic Ripper

    ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER HANDLE HYDRAULIC RIPPER This ripper is applicable for D65EX and D65WX dozers. GENERAL VIEW (1) Hydraulic cylinder (4) Shank (2) Link (5) Point (3) Beam (6) Support...

  • Page 455: Explanation Of Components

    HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER WARNING When performing inspection or maintenance of the machine, or when parking the machine, lower the ripper to the ground and set the work equipment lock lever to LOCK position. The ripper control lever is used for operating the ripper.

  • Page 456: Machine Operations And Controls

    ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER MACHINE OPERATIONS AND CONTROLS CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE METHOD FOR WALK-AROUND CHECK Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the rivets.
  • Page 457 HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS ADJUST WORK EQUIPMENT METHOD FOR ADJUSTING DIGGING DEPTH There are mounting pin holes on the shank. Select one of them, depending on the digging depth. Max. digging depth Pin hole position ( mm ( in)) When there is special 585 (23.0) need to dig...
  • Page 458 ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER METHOD FOR REPLACING RIPPER POINT A point is installed to protect the shank. If the point is worn, replace it according to the following procedure. Put a pin puller to the pin indicated by the arrow, and hit it with a hammer to drive out the pin.

  • Page 459: Troubles And Actions

    OTHER TROUBLE • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...

  • Page 460: Handle 3M Width Blade

    ATTACHMENTS AND OPTIONS HANDLE 3m WIDTH BLADE HANDLE 3m WIDTH BLADE This blade is applicable for D65PX and D65WX. GENERAL VIEW (1) Center blade (6) Lock pin (2) Folding blade (R.H and L.H.) (7) Shim (for offset pin) (3) Offset pin (8) Shim (for hinge pin) (4) Hinge pin (9) Lock plate...

  • Page 461: Machine Operations And Controls

    HANDLE 3m WIDTH BLADE ATTACHMENTS AND OPTIONS MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS CAUTION • Use the 3 m wide blade for light dozing work or level- ing work. • Do not dig hard/frozen ground by using the right and left folding portions of the blade or perform severe work such as stumping, ditching, etc.

  • Page 462: Transportation

    ATTACHMENTS AND OPTIONS HANDLE 3m WIDTH BLADE TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION PROCEDURE As a basic rule, always transport the machine on a trailer. When selecting the trailer, refer to the weight and dimensions shown in “SPECIFICATIONS (6-14)”. Note that the mass and dimensions for transportation shown in “SPECIFICATIONS”...
  • Page 463 HANDLE 3m WIDTH BLADE ATTACHMENTS AND OPTIONS CAUTION • When lock plate (6) is removed, lock pin (5) falls. Re- move lock plate (6) with care. • At this time, do not remove hinge pin (8) in the rear of the blade.

  • Page 464: Check And Maintenance

    ATTACHMENTS AND OPTIONS HANDLE 3m WIDTH BLADE CHECK AND MAINTENANCE WHEN REQUIRED METHOD FOR ADJUSTING PLAY IN BLADE BOSS WARNING It is dangerous if the work equipment moves by mistake when the blade is adjusted. Set the work equipment in a stable condition, then stop the engine. Securely set the work equipment lock lever and parking brake lever to the respective LOCK positions.

  • Page 465: Specifications

    HANDLE 3m WIDTH BLADE ATTACHMENTS AND OPTIONS SPECIFICATIONS Power angle power tilt dozer (3m wide blade) Item Unit D65PX-18, D65WX-18 Overall length (When unfolded)  mm (ft  in) 4010 (13’ 2”) Overall length (When folded)  mm (ft  in) 2990 (9’ 10”) Overall blade width (When folded)  mm (ft  in) 2960 (9’...

  • Page 466: Replacement Parts

    REPLACEMENT PARTS...

  • Page 467: Periodic Replacement Of Defined Life Parts

    Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...

  • Page 468: Consumable Parts

    The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
  • Page 469 CONSUMABLE PARTS REPLACEMENT PARTS Weight Replacement inter- Item Part No. Part name Q'ty ( kg ( lb)) 42.6 14X-72-51610 Cutting edge (center) (93.9) D65PX, 24.3 D65WX 13G-72-61420 Cutting edge (side) (53.6) Power • 14Y-71-11330 End bit (left) angle power tilt 14Y-71-11340 End bit (right) dozer (02090-11270) (Bolt)
  • Page 470 REPLACEMENT PARTS CONSUMABLE PARTS Weight Replacement inter- Item Part No. Part name Q'ty ( kg ( lb)) 25.7 14X-952-5180 Cutting edge (left of center) (56.7) 30.4 14X-952-5381 Cutting edge (right of center) (67.0) D65WX 14X-952-5120 Cutting edge (left) (20.1) Sigma • dozer 14X-952-5190 Cutting edge (right) Blade...

  • Page 471: Recommended Fuel, Coolant, And Lubricant

    Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...

  • Page 472: Lubrication Chart

    REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT LUBRICATION CHART • The lubrication chart uses symbols to show the lubrication points and types of lubricant by each lubrication interval. • Even if the same symbol is used in the lubrication chart, the recommended genuine oil may differ according to the lubricated location and the ambient temperature.
  • Page 473 RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS Power angle power tilt dozer • The symbols used in the lubrication chart are explained as follows.

  • Page 474: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature

    REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ASTM: American Society of Testing and Material...
  • Page 475 Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems in the cooling system, including the engine.
  • Page 476 INDEX INDEX Symbols Air conditioner - Start manual operation..... 3-255 Air conditioner - Stop automatic operation..3-254 12H24H display mode - Switch......3-87 Air conditioner - Stop manual operation....3-256 2 workers for maintenance when engine is running..Air conditioner compressor drive belt - Check tension................2-33 ...............4-41 3m wide blade - Handle..........
  • Page 477 Brake - Check performance........4-61 Cutting edge and end bit - Invert / Replace..4-30 Brake - Use............2-27 Brake on downhill..........3-219 Brake pedal............3-106 D65EX-18 specifications.........5-2 Brake pedal - Check stroke.........3-166 D65PX-18 - Specifications........5-3,5-4 Brake system caution lamp........3-23 Damper case - Change oil........4-81 Buzzer cancel switch..........
  • Page 478 INDEX Engine - Operate/Check before starting..... 3-189 Fresh and clean lubricants........4-2 Engine - Start..........3-193,3-285 Freshrecirc air changeover switch...... 3-250 Engine - Start in cold weather......3-194 Front wiper - Replace..........4-39 Engine - Start in normal weather......3-193 Fuel................. 4-6 Engine - Start with jumper cables....2-24,3-284 Fuel - Check level / Add........3-167 Engine - Stop............
  • Page 479 Keep machine clean..........2-12 High-pressure hoses and pipings - Handle...2-37 Komatsu Closed Crankcase Ventilation (KCCV) 3-139 High-voltage cables - Caution not go close..2-20 Komatsu Diesel Particulate Fillter (KDPF) - Handle..Horn - Check operation........3-174 ..............3-128 Horn switch............3-98 Komatsu genuine lubricants........4-2 Hydraulic circuit - Bleed air......
  • Page 480 INDEX Machine - Travel on load........3-267 Machine - Turn during forward travel....3-214 Observance of the applicable laws and regulations, Machine - Turn gradually during forward travel on exemption............ 3-156 downhill slope..........3-216 Off season - Check..........4-42 Machine - Turn normally........3-214 OFF switch............3-247 Machine - Turn on downhill slope.......
  • Page 481 INDEX Precautions for floating operation....... 3-221 Preset - Register..........3-265 Precautions for getting on or off machine..... 2-15 Preset button............3-262 Precautions for high voltage......... 2-38 Prevent fire............2-13 Precautions for high-pressure fuel......2-37 Product information..........1-7 Precautions for high-pressure grease when adjusting Prohibited operations........2-27,6-10 track tension..........
  • Page 482 INDEX Shim for assembly of work equipment - Adjust...3-226 Shims at trunnion - Adjust........4-50 Warning display.............3-15 Shovel holder............3-117 Warning tag during inspection and maintenance - Dis- Sound balance - Adjust........3-265 play..............2-31 Sound control button...........3-262 Warning tags - Use..........2-22 Specifications..........5-2,6-14 Water pump - Check..........
  • Page 483 D65EX-18, D65PX-18, D65WX-18 BULLDOZER Form No. TEN00653-01 ©2014 KOMATSU All Right Reserved Printed in Japan 11-2014...

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