Page 1 Maintenance Manual D65EX -15E0 D65PX -15E0 BULLDOZER SERIAL NUMBER D65EX-15E0 - 69001 and up D65PX-15E0 - 69001 and up WARNING 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.
Page 3 FOREWORD...
Page 4: Foreword
FOREWORD BEFORE READING THIS MANUAL BEFORE READING THIS MANUAL This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
Page 5 FOREWORD BEFORE READING THIS MANUAL The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication. Continuing improvements in the design of this machine may lead to addi- tional changes that are not reflected in this manual.
Page 6: Important Safety Information
FOREWORD IMPORTANT SAFETY INFORMATION IMPORTANT SAFETY INFORMATION To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed.
Page 7: Noise Emission Levels
FOREWORD IMPORTANT SAFETY INFORMATION Noise emission levels Two labels indicating the machine noise level are affixed on the machine. q Sound pressure level at the operator's station, measured according to ISO6396 (Dynamic test method, simulated working cycle) q Sound power level emitted by the machine, measured according to ISO 6395 (Dynamic test method, simulated working cycle).
Page 8: Guide To Reduce Vibration Levels On Machine
FOREWORD IMPORTANT SAFETY INFORMATION These values were determined using a representative machine and measured during the typical operating condi- tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and ISO 5349. Operating condition: (WHEEL LOADER:) V-shape loading (HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating) (TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion...
Page 9 FOREWORD IMPORTANT SAFETY INFORMATION 8. The following guidelines can be effective to minimize risks of low back pain q Operate the machine only when you are in good health. q Provide breaks to reduce long periods of sitting in the same posture q Do not jump down from the cab or machine q Do not repeatedly handle and lift loads.
Page 10: Intended Use
FOREWORD INTENDED USE INTENDED USE USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: q Dozing q Smoothing q Cutting into hard or frozen ground or ditching q Felling trees, removing stumps See the section “WORK POSSIBLE USING BULLDOZER (3-88)“ for further details. GENERAL VIEW AND DIRECTIONS OF MACHINE In this manual, the directions of the machine (front,rear,left,right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine.
Page 11: Visibility From Operator's Seat
FOREWORD INTENDED USE VISIBILITY FROM OPERATOR'S SEAT The visibility standards (ISO 5006) for this machine require a view shown in the diagram below. PROXIMITY VISIBILITY The figure bellows shows a front visibility from the machine at a spot 1.0 m away from the side and 1.5 m above the ground.
Page 12: Breaking-In The New Machine
FOREWORD INTENDED USE BREAKING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How- ever, operating the machine under full load before breaking the machine in can adversely affect the perfor- mance and shorten the machine life.
Page 13: Location Of Plates, Table To Enter Serial No. And Distributor
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR When ordering replacement parts, please inform your Komatsu distributor of the following. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is at the front bottom right of the operator's seat.
Page 14: Additional Epa Nameplate
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ADDITIONAL EPA NAMEPLATE The additional EPA nameplate is located on top of the engine head cover on the left side of the machine. EPA: Environmental Protection Agency, U.S.A. SERVICE METER POSITION The service meter is provided at the lower part of the monitor panel.
Page 15 FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product Identification Number (PIN) Manufacturers name: KOMATSU LTD. Address: 3-6 Akasaka Minato-ku, 101 Tokyo Japan Distributor Address Phone Service personnel for your...
Page 16: Machine Serial Number Plate
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR MACHINE SERIAL NUMBER PLATE Model Seriel Number Manufacturing year Weight Engine power Product Identification Number Manufacturer 1-14...
Page 17: Table Of Contents
CONTENTS CONTENTS FOREWORD BEFORE READING THIS MANUAL........................1-2 IMPORTANT SAFETY INFORMATION ....................... 1-4 Noise emission levels ..........................1-5 Vibration levels............................1-5 Guide to Reduce Vibration Levels on Machine.................. 1-6 INTENDED USE ..............................1-8 USE OF MACHINE ............................. 1-8 GENERAL VIEW AND DIRECTIONS OF MACHINE ................. 1-8 VISIBILITY FROM OPERATOR'S SEAT....................
Page 18 CONTENTS GENERAL VIEW OF CONTROLS AND GAUGES..................3-3 EXPLANATION OF COMPONENTS........................3-6 FRONT PANEL ............................3-6 CHECK MONITOR SYSTEM ......................3-7 EMERGENCY CAUTION ITEMS ...................... 3-8 CAUTION ITEMS..........................3-10 METER GROUP ..........................3-12 LAMPS............................. 3-16 SWITCHES ............................3-18 METHOD OF USING MAINTENANCE MODE ................3-22 SWITCHES ...............................
Page 19 CONTENTS STARTING IN COLD WEATHER ....................3-74 STOPPING ENGINE..........................3-75 MACHINE OPERATION ........................... 3-77 MOVING MACHINE......................... 3-77 STOPPING MACHINE........................3-79 SHIFTING GEARS............................ 3-79 GEARSHIFTING OPERATION......................3-80 GEARSHIFTING OPERATION USING PRESET MODE FUNCTION ..........3-80 AUTO DOWN SHIFT OPERATION....................3-82 SHIFTING BETWEEN FORWARD AND REVERSE ................3-83 STEERING MACHINE ..........................
Page 20 CONTENTS LOADING, UNLOADING WORK ......................3-102 LIFTING MACHINE..........................3-105 TRAVELING ON ROADS ........................3-107 COLD WEATHER OPERATION ........................3-108 PRECAUTIONS FOR LOW TEMPERATURE ..................3-108 AFTER COMPLETION OF WORK ......................3-109 AFTER COLD WEATHER ........................3-109 LONG-TERM STORAGE..........................3-110 BEFORE STORAGE..........................3-110 DURING STORAGE ..........................
Page 21 CONTENTS USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .... 4-13 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL............................4-15 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..............4-16 TORQUE LIST ............................4-16 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................4-17 SAFETY CRITICAL PARTS........................
Page 22 CONTENTS CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ..............4-46 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ..............4-47 CHECK LEVEL OF BATTERY ELECTROLYTE ................4-48 CHECK, CLEAN ADDITIONAL FUEL STRAINER ................4-49 CHECK BRAKE PERFORMANCE ....................4-50 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..........
Page 23 CONTENTS HANDLING HYDRAULIC RIPPER........................6-3 GENERAL VIEW............................6-3 EXPLANATION OF COMPONENTS ......................6-4 OPERATION............................... 6-5 CHECK BEFORE STARTING ENGINE, ADJUST ................6-5 PRECAUTIONS WHEN OPERATING....................6-5 ADJUSTING POSTURE OF WORK EQUIPMENT ................6-5 TROUBLESHOOTING..........................6-7 OTHER TROUBLE ..........................6-7 MAINTENANCE............................6-7 EVERY 250 HOURS SERVICE......................
Page 24 CONTENTS 1-22...
Page 25: Safety
SAFETY WARNING Please read and make sure that you fully understand the precautions discribed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precaustions strictly.
Page 26: Important Safety Information
SAFETY IMPORTANT SAFETY INFORMATION IMPORTANT SAFETY INFORMATION SAFETY LABELS..............................2-42 POSITION FOR ATTACHING SAFETY LABELS ....................2-52 SAFETY LABELS............................... 2-52 PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE............... 2-102 FOR SAFE OPERATION ..........................2-102 KNOW YOUR EQUIPMENT ..........................2-102 PREPARE FOR SAFE OPERATION ....................... 2-102 CLOTHING AND PERSONAL PROTECTIVE ITEMS ..................
Page 27 SAFETY IMPORTANT SAFETY INFORMATION PREVENTION BURNS FROM HOT WATER ....................2-262 PREVENTION BURNS FROM HOT OIL ......................2-262 COMPRESSED AIR............................2-262 HANDLING HIGH-PRESSURE HOSES, PIPING.................... 2-262 PRECAUTIONS WITH HIGH-PRESSURE OIL ....................2-272 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION..... 2-272 DO NOT DISASSEMBLE RECOIL SPRING....................
Page 28: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS The following safety labels are used on this machine. q Make sure that you fully understand the location and content of each safety label, together with the means of avoiding the danger shown. q To ensure that the contents of safety labels can be read properly, be sure that they are in the correct place and always keep them clean.
Page 29: Position For Attaching Safety Labels
SAFETY SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS (1) Caution before operating or maintaining machine (09651-A0641) q Warning! q Read manual before operation, maintaince, disassembly, assembly and transportation.
Page 30 SAFETY SAFETY LABELS (2) Caution before moving in reverse (09802-B0750) (3) Caution for leaving operator's seat (09654-B0641) q Sign indicates a hazard of unexpected moving of stopped machine. q Lower working device to ground, move safety lever to lock position and take engine key with you before leaving machine.
Page 31 SAFETY SAFETY LABELS (5) Caution for accumulator (09659-A057B) q There is the hazard of explotion causing injury. q Do not disassemble the accumulator, make holes in it, weld it, cut it, hit it, roll it or bring it near flame. (6) Caution for adjusting track tension (09657-A0881) The safety label is attached to the rear side of the track adjust- ment window cover.
Page 32 SAFETY SAFETY LABELS (9) Caution for approach when machine moving (09806-B1201) q Sign indicates a hazard of being run over by moving equip- ment. q Keep a safe distance from equipment when it is moving. (10) Prohibition of jump start (09842-A0481) q Start the engine only after sitting down in the operator’s seat.
Page 33 SAFETY SAFETY LABELS (12) Caution for FOPS (09620-C2000) FOPS CERTIFICATION This protective structure was provided to comply with the following standard. 1. MODEL 2. MACHINE MODEL 3. SERIAL NO. 4. FOPS LEVEL No. q If some modification is applied to the FOBS. It might not enough strength and might not be complied with the standard.
Page 34: Precautions Common To Operation And Maintenance
SAFETY PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE Improper operation and maintenance can cause serious injury or death. Read the manual and safety labels before operating or servicing the machine. Follow all warnings and instructions. FOR SAFE OPERATION For safe operation of this machine, you must be a qualified and authorized operator.
Page 35: Clothing And Personal Protective Items
SAFETY PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE CLOTHING AND PERSONAL PROTECTIVE ITEMS To avoid the risk of injury: q Do not wear jewelry while in operation. You may catch on the control lever or a protruding part and fall off. q Do not wear loose clothes while in operation.
Page 36: Handrails And Steps
SAFETY PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE HANDRAILS AND STEPS To avoid risk of injury when getting on or off the machine. q When getting on or off the machine, always face the machine and maintain three- point contact (both feet and one hand or one foot and both hands) with the handrails, steps (and also track shoes) to ensure that you support yourself securely.
Page 37: Precautions When Standing Up From Operator's Seat
SAFETY PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE q Do not bring any dangerous items, such as explosives or items that may ignite, into the operator's compart- ment. PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT When standing up from the operator's seat, always lower the work equipment to the ground, operate work equipment lock lever (1) and parking brake lever (2) to the LOCK (L) position and stop the engine.
Page 38: Fire Prevention
SAFETY PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE FIRE PREVENTION q Fire coming from fuel, oil, antifreeze, window washer fluid Fuel, oil, antifreeze, and window washer fluid will ignite if brought close to a flame, so there is danger of fire. Always obey the following.
Page 39: Action If Fire Occurs
SAFETY PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE q Fire coming from hydraulic line Fix the cushions of the piping, guards, tubes, and hoses securely. q Explosion caused by lighting equipment Use explosion-proof lighting equipment when inspecting the fuel, oil, battery fluid, window washer fluid, or coolant.
Page 40: Precautions Related To Ventilation Of Exhaust Gas
SAFETY PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Danger of sparks If sparks are generated, they may fly and cause serious personal injury. Always obey the following. q Do not short-circuit the battery terminals through contact with metallic objects, such as tools, across the terminals.
Page 41: Precautions During Operation
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS DURING OPERATION EXAMINATION AND CONFIRMATION OF WORKSITE Before starting operations, check first if there is any danger on the jobsite. If you do not understand the dangers of the jobsite before starting operations, the machine may tip over, or the ground may collapse, or rocks may fall, causing injury to the operator.
Page 42: Ensure Good Visibilty
SAFETY PRECAUTIONS DURING OPERATION ENSURE GOOD VISIBILTY When the machine is run or operated in a jobsite of low visibility, there is always a possibility that an operator gets injured or causes a serious bodily injury, because they cannot see an obstacle around the machine or check the conditions at the jobsite.
Page 43: Precautions When Starting
SAFETY PRECAUTIONS DURING OPERATION q Adjust the operator's seat so that it is easy to see to the front, and check that there is no damage or wear to the seatbelt or seatbelt mounts. q Check that the gauges work normally and that the control levers are in the neutral position. q Before starting up the engine, check that the work equipment lock lever is in the LOCK position.
Page 44: Check Before Starting Operation
SAFETY PRECAUTIONS DURING OPERATION CHECK BEFORE STARTING OPERATION Before starting the engine, carry out the “CHECK BEFORE STARTING (3-54)“ to confirm that there is no problem with operating the machine. If this check is not carried out properly, there is danger that it may lead to damage dur- ing operation or may lead to serious personal injury.
Page 45: Precautions When Traveling
SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS WHEN TRAVELING q To avoid accidents caused by coming in contact with peo- ple, structures, and other machines, always maintain the proper distance when traveling. q When traveling the machine on a flat land, hold the work equipment at height (A) of 40 cm to 50 cm above the ground.
Page 46: When Towing
SAFETY PRECAUTIONS DURING OPERATION WHEN TOWING For towing, see “METHOD OF TOWING MACHINE (3-112)“. q Always confirm that the wire rope or drawbar used for tow- ing has ample strength for the weight of the machine being towed. q Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C).
Page 47: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE UNAUTHORIZED MODIFICATION If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as machine strength and visibility.
Page 48: Proper Tools
SAFETY PRECAUTIONS FOR MAINTENANCE PROPER TOOLS Always use the correct tools and handle them properly. Using damaged or deformed tools or using tools for the wrong pur- pose may cause injury. SELECTION WORK PLACE FOR MAINTENANCE When selecting the place to carry out inspection and maintenance, use flat firm ground that is safe for the opera- tion, with no danger of landslide, falling rocks, or flooding.
Page 49: Two Workers For Inspection And Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR INSPECTION AND MAINTENANCE WHEN ENGINE IS RUNNING q Lower the work equipment to the ground and stop the engine. q Operate work equipment lock lever (1) and parking brake lever (2) to the LOCK (L) position. q Keep away from rotating parts.
Page 50: Precautions When Using Hammer
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN USING HAMMER In the work using a hammer, there is always a risk that a pin or metal chips are sent flying, causing a serious personal injury. If a flying metal chip gets in your eye, you may lose your eye- sight.
Page 51: Precautions With High-Pressure Oil
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WITH HIGH-PRESSURE OIL Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes and cause serious injury, blindness or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not use your bare hand.
Page 52: Accumulator
SAFETY PRECAUTIONS FOR MAINTENANCE ACCUMULATOR The accumulator contains highly pressurized nitrogen gas. A failure to properly handle it can lead to an explosion, causing a serious personal injury. q Do not remove or disassemble unless necessary. q Do not bring it near flame or dispose of it in fire. q Do no make holes in it weld it, or use a cutting torch.
Page 53: Precautions For Machine
SAFETY PRECAUTIONS FOR MACHINE PRECAUTIONS FOR MACHINE PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) When the machine rolls over, ROPS built in the operator's cab absorbs the shock energy by supporting the machine's weight. Thus an operator is protected from an accident. If this function is hampered, a ROPS cab can no longer protect an operator from injury.
Page 54 SAFETY PRECAUTIONS FOR MACHINE 2-30...
Page 55: Operation
OPERATION WARNING Please read and make sure that you understand the SAFETY section before reading this section.
Page 56: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Machine equipped with ROPS cab Machine equipped with ROPS canopy Blade Sprocket Tilt cylinder Track frame Lift cylinder Frame (10) Idler ROPS guard (11) ROPS canopy Track shoe...
Page 57: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Machine equipped with cab Parking brake lever (12) Fan rotation selector switch Work equipment lock lever (13) Starting switch Cigarette lighter (14) Information switch Fuel control dial (15) Buzzer cancel switch Steering, forward-reverse, gear shift lever (16) Brake pedal Auto shift down switch...
Page 58 OPERATION GENERAL VIEW Machine equipped with ROPS canopy Parking brake lever (10) Fan rotation selector switch Work equipment lock lever (11) Information switch Fuel control dial (12) Buzzer cancel switch Steering, forward-reverse, gear shift lever (13) Starting switch Auto shift down switch (14) Brake pedal Preset mode switch (15) Decelerator pedal...
Page 59 OPERATION GENERAL VIEW MONITOR PANEL Display panel A (Speed range, Engine speed) (10) Warning lamp Power train oil temperature gauge (11) Engine coolant temperature caution lamp Engine coolant temperature gauge (12) Maintenance caution lamp Hydraulic oil temperature gauge (13) Engine pre-heating pilot lamp Fuel level gauge (14) Engine oil pressure caution lamp Hydraulic oil temperature caution lamp...
Page 60: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. FRONT PANEL Emergency caution items Lamp...
Page 61: Check Monitor System
OPERATION EXPLANATION OF COMPONENTS CHECK MONITOR SYSTEM MONITOR SYSTEM NOTICE q Stop the machine on level ground and carry out the monitor check. q Stop the engine, then turn the starting switch to the ON position and check that the lamps light up for approx.
Page 62: Emergency Caution Items
OPERATION EXPLANATION OF COMPONENTS EMERGENCY CAUTION ITEMS CAUTION If any of the caution lamps begins to flash, stop the engine or reduce the engine speed to low idle immedi- ately and check the trouble spot for necessary actions. These items must be monitored when the engine is running. If there is any problem, the caution lamp for the loca- tion of the problem and warning lamp (A) flash, and the alarm buzzer sounds intermittently.
Page 63 OPERATION EXPLANATION OF COMPONENTS ENGINE COOLANT TEMPERATURE CAUTION LAMP This lamp (2) indicates a rise in the coolant temperature. When the monitor lamp flashes, run the engine at low idle speed until green range of the engine coolant temperature gauge lights. POWER TRAIN OIL TEMPERATURE CAUTION LAMP This lamp (3) indicates a rise in the oil temperature of the torque converter outlet.
Page 64: Caution Items
OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If these caution lamps flash, check and repair the appropriate location as soon as possible. These are items which need to be observed when the engine is running. If any problem occurs, the item needing immediate repair is displayed.
Page 65 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE CAUTION LAMP This lamp (2) lights up for approx. 30 seconds after the starting switch is turned to the ON position if the filter or oil replacement interval has been reached. After replacing the indicated filter or oil displayed on display panel B (multi-information), reset the interval.
Page 66: Meter Group
OPERATION EXPLANATION OF COMPONENTS METER GROUP Engine coolant temperature gauge Engine pre-heating pilot lamp Power train oil temperature gauge Display panel A Hydraulic oil temperature gauge (Speed range display, Engine speed) Fuel leve gauge Display panel B (multi-information) ENGINE COOLANT TEMPERATURE GAUGE NOTICE If the coolant temperature gauge often enters red range (C), check the radiator for clogging.
Page 67 OPERATION EXPLANATION OF COMPONENTS POWER TRAIN OIL TEMPERATURE GAUGE NOTICE If the power train oil temperature gauge often enters the red range (C), we recommend you to lower the travel speed one range (for example, F2 → F1) to reduce the load on the power train when operating. Gauge (2) indicates the torque converter outlet oil temperature.
Page 68 OPERATION EXPLANATION OF COMPONENTS ENGINE PRE-HEATING PILOT LAMP This lamp (5) indicates that the engine is being preheated with an electric heater in cold weather. When the engine starting switch is turned to the ON position, the engine controller detects the engine coolant temperature and automatically starts to preheat the engine at low tempera- ture.
Page 69 OPERATION EXPLANATION OF COMPONENTS The following information is displayed by the operating mode. Top line (A): Action code If any problem occurs on the machine, an action code is dis- played. If an action code appears, take the applicable action. For details, see “OTHER TROUBLE (3-117).
Page 70: Lamps
OPERATION EXPLANATION OF COMPONENTS LAMPS Warning lamp Fan operation confirmation lamp Filter/oil replacement interval lamp WARNING LAMP (Red) NOTICE If alarm buzzer sounds, stop work immediately and perform inspection and maintenance of the appropri- ate point. This lamp (1) flashes when the caution lamp flashes and when an action code is displayed on display panel B (multi-informa- tion).
Page 71 OPERATION EXPLANATION OF COMPONENTS FILTER/OIL REPLACEMENT INTERVAL LAMP (Yellow) If it is time to replace a filter or change the oil, this lamp (2) lights up or flashes for approx. 30 seconds after the starting switch is turned ON. REMARK This lamp (2) lights up if there is less than 30 hours remaining until replacement, and flashes when the replacement interval has passed.
Page 72: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Machine equipped with cab Machine equipped with ROPS canopy Starting switch Rear lamp switch Auto shift down switch Fan rotation selector switch Preset mode switch Information switch Head lamp switch Buzzer cancel switch 3-18...
Page 73 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (1) is used to start or stop the engine. (A): OFF position At this position, the starting switch key can be inserted and removed. When the switch is turned to this position, all the electric circuits are turned off and the engine stops.
Page 74 OPERATION EXPLANATION OF COMPONENTS HEAD LAMP SWITCH This switch (4) lights up when the front lamp, and panel lamp light up. Q (OFF) position: Lights out (ON) position: Lights on REAR LAMP SWITCH This switch (5) lights up the rear lamps. Q (OFF) position: Lights out (ON) position: Lights on FAN ROTATION SELECTOR SWITCH...
Page 75 OPERATION EXPLANATION OF COMPONENTS REMARK The fan rotation direction cannot be changed, even if it is tried when the engine is running. The fan operation confirmation lamp begins to flash to tell you that the fan rotation direction cannot be changed. When the fan operation check lamp lights up and the fan is turning in the reverse direction, the machine does not start even if the steering - forward / reverse shifting- gearshift lever...
Page 76: Method Of Using Maintenance Mode
OPERATION EXPLANATION OF COMPONENTS When display panel B (multi-information) is in the maintenance mode t position: Cancel or reset to operation mode U position: Confirms selection or selected item For details, see “METHOD OF USING MAINTENANCE MODE (3-22)“. METHOD OF USING MAINTENANCE MODE To switch from the operation mode to the maintenance mode, turn the buzzer cancel switch to the U position and hold it there for at least 2.5 seconds.
Page 77 OPERATION EXPLANATION OF COMPONENTS METHOD OF SELECTING EACH MODE Operating mode (Hold for 2.5 sec) Oil/filter maintenance mode Detailed item display PM clinic auxiliary mode Detailed item display Fault code display mode Detailed item display Adjustment mode Detailed item display (To oil/filter maintenance mode) METHOD OF USING OIL AND FILTER MAINTENANCE MODE NOTICE...
Page 78 OPERATION EXPLANATION OF COMPONENTS In the oil and filter maintenance mode, the replacement inter- vals for oil and filters are displayed on display panel B (multi- information). (1) The item is displayed. (2) The time remaining until replacement is displayed. (3) The quantity of replacements until now is displayed.
Page 79 OPERATION EXPLANATION OF COMPONENTS REMARK To return to the maintenance mode, operate the buzzer cancel switch to t. METHOD OF USING PM CLINIC AUXILIARY MODE CAUTION When moving the work equipment or setting the transmission to the travel position for carrying out mea- surements, check carefully that the situation is safe.
Page 80 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING FAULT CODE DISPLAY MODE NOTICE The fault items observed by this function are connected with the electronic control, so even if a fault code is not displayed, there is probably some problem with the machine. If the operator feels any problem with the machine, the machine should be stopped immediately and checked.
Page 81 OPERATION EXPLANATION OF COMPONENTS 3. The brightness can be adjusted by operating the informa- tion switch. The higher the number, the brighter the screen becomes; the lower the number, the darker the screen becomes. > position: Number increases < position: Number decreases 4.
Page 82 OPERATION EXPLANATION OF COMPONENTS 8. When the buzzer cancel switch is operated to U, the brightness of the display panel B (multi-information) back- lighting is set. REMARK To return to the maintenance mode, operate the buzzer cancel switch to t. The brightness of the backlighting of the monitor panel differs according to whether the front lamp is lit or not.
Page 83: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Machine equipped with cab Machine equipped with ROPS canopy Fuel control dial Cigarette lighter Horn switch Accessory socket Room lamp switch Rear glass heating switch Wiper switch (EU specification) 3-29...
Page 84 OPERATION EXPLANATION OF COMPONENTS FUEL CONTROL DIAL Dial (1) is used to control the engine speed and output. (a) Low idling position: Turn fully to the left (b) High idling position: Turn fully to the right HORN SWITCH The horn sounds when the button (2) at the rear of the blade control lever at the right side of the operator's seat is pressed.
Page 85 OPERATION EXPLANATION OF COMPONENTS q Wiper only (J) ON position: Wiper is operated (K) OFF position: Wiper stops q Wiper and window washer If this is kept pressed to the ON position (J) while the wiper is working, water will be sprayed out. q Only wind washer If this is kept to the OFF position (K), water will be sprayed out.
Page 86 OPERATION EXPLANATION OF COMPONENTS CIGARETTE LIGHTER This (5) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its origi- nal position after a few seconds, so take it out to light your cig- arette.
Page 87: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Work equipment lock lever Brake pedal Parking brake lever Decelerator pedal Steering, forward-reverse, gear shift lever Blade control lever WORK EQUIPMENT LOCK LEVER WARNING q When leaving the operator's compartment, set the work equipment lock lever securely to the LOCK position.
Page 88 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE LEVER WARNING q When parking the machine, always set the parking brake lever in the LOCK position. q If the parking brake lever is operated, the brake is applied, even when the machine is traveling. The machine will suddenly stop, so this is dangerous.
Page 89 OPERATION EXPLANATION OF COMPONENTS Gear shifting When UP switch (U) or DOWN switch (D) is pushed, the trans- mission speed will change. UP switch (U): Each time the switch is pressed, the transmis- sion will up shift one speed. DOWN switch (D): Each time the switch is pressed, the trans- mission will down shift one speed.
Page 90 OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING Do not place your foot on this pedal unnecessarily. Depress the pedal (4) to apply the right and left brakes. DECELERATOR PEDAL WARNING q Do not place your foot on this pedal unnecessarily. q When passing over the top of a hill or when a load is dumped over a cliff, the load is suddenly reduced, so there is danger that the travel speed will also increase suddenly.
Page 91 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER POWER TILTDOZER This lever (6) is used to lift or tilt the blade. q Lifting control (A) RAISE: Blade goes up (B) HOLD: Blade is stopped and held in this position. (C) LOWER: Blade goes down (D) FLOAT: Blade will move freely according to external force.
Page 92 OPERATION EXPLANATION OF COMPONENTS POWERTILT POWER PITCHDOZER This lever (6) is used to lift or tilt and pitch the blade. q Lifting control (A) RAISE: Blade goes up (B) HOLD: Blade is stopped and held in this position. (C) LOWER: Blade goes down (D) FLOAT: Blade will move freely according to external force.
Page 93 OPERATION EXPLANATION OF COMPONENTS q Pitch control After moving the lever to the neutral position without fail, tilt the blade while pressing any of the switches (M) in the center of the knob. Then the angle of the blade edge changes. (B) Hold: The blade stops and holds a stationary posture.
Page 94 OPERATION EXPLANATION OF COMPONENTS ANGLE DOZER This lever (6) is used to lift or tilt the blade. q Lifting control (A) RAISE: Blade goes up (B) HOLD: Blade is stopped and held in this position. (C) LOWER: Blade goes down (D) FLOAT: Blade will move freely according to external force.
Page 95: Circuit Breaker
OPERATION EXPLANATION OF COMPONENTS CIRCUIT BREAKER NOTICE q When resetting the circuit breaker, always turn off the power first (turn the starting switch OFF). q If the reset button for the circuit breaker comes out immediately when it is pushed in, it is necessary to carry out an inspection of the electrical circuit.
Page 96 OPERATION EXPLANATION OF COMPONENTS q Chassis Fuse boxes (A) and (B) are installed under the battery cover. q Cab (machines equipped with cab) Fuse box (C) is installed in the overhead panel. FUSE CAPACITY AND CIRCUIT NAME Fuse box (A) Fuse Circuit capacity...
Page 97: Fusible Link
OPERATION EXPLANATION OF COMPONENTS Fuse box (C) Fuse Circuit capacity Radio memory Radio,lamp,cigarette lighter Heated glass (EU specification) Rear wiper Front wiper Left and right door wiper FUSIBLE LINK If any of the electrical equipment in the operator's cab does not work, a fusible link built in the wiring harness is suspected of disconnection.
Page 98: Machine Equipped With Rops Canopy
OPERATION EXPLANATION OF COMPONENTS MACHINE EQUIPPED WITH ROPS CANOPY NOTICE q Do not use as a power supply for 12V equipment. This will cause failure of the equipment. q When using as a power supply pickup, do not install equipment which exceeds 120W (24V x 5A). 1.
Page 99: Sash Glass Intermediate Lock
OPERATION EXPLANATION OF COMPONENTS SASH GLASS INTERMEDIATE LOCK (Machine equipped with cab) When working with the cab sash glass open, use this lock to prevent the glass from chattering. q When the lever is in the FREE position (F), the glass can be opened or closed.
Page 100: Opening And Closing Engine Side Cover
OPERATION EXPLANATION OF COMPONENTS OPENING AND CLOSING ENGINE SIDE COVER When opening Pull door release lever (1) to release the lock, then pull the cover up. When closing NOTICE When closing the cover, always release the gas damper lock first. If the gas damper lock is not released and any attempt is made to close the cover, the gas damper may break.
Page 101: Cup Holder
OPERATION EXPLANATION OF COMPONENTS CUP HOLDER (If equipped) This is the place to put cans or cups. If drinks are put in places other than the cup holder, the can or cup will fall over and make the surrounding area or equipment dirty.
Page 102: Air Conditioner, Handling
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER, HANDLING (Machine equipped with cab) (if equipped) By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it pos- sible to provide a pleasant working environment even on dusty jobsites. GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL Fan switch Defroster...
Page 103 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidi- fying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
Page 104: Method Of Operation
OPERATION EXPLANATION OF COMPONENTS The settings for each mode are retained in memory even when the starting switch is turned OFF. However, in the following cases, the settings must be reset. q When the machine has been out of use for more than 7 days q When the battery voltage is extremely low q When there has been abnormal interference from outside q When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch)
Page 105: Precautions When Using
OPERATION EXPLANATION OF COMPONENTS COOL BOX When the cooling is being used, this can be used for keeping drinks and other things cool. When the heating is being used, it can be used to keep things warm. Do not use the cool box for things which smell or leak water or break easily.
Page 106: Check Compressor Belt Tension And Refrigerant (Gas) Level
OPERATION EXPLANATION OF COMPONENTS REMARK The replacement interval may become shorter depending on the conditions during use. If the receiver is used when the moisture absorption limit of the desiccant has been exceeded, the refrigerant cir- cuit may become blocked and cause the compressor to break down. PRECAUTIONS WHEN REPLACING RECEIVER q If the receiver is left for more than 15 minutes with the blind cover removed, the moisture in the air will be absorbed, and this will reduce the life of the desiccant.
Page 107: Operation
OPERATION OPERATION OPERATION CHECK BEFORE STARTING ENGINE, ADJUST WALK-AROUND CHECK Before starting the engine, look around and under the machine to check for loose nuts and bolts, or leakage of oil, fuel, or coolant, and check condition of the work equipment and hydraulic system. Also check for loose wiring, play, and accumulation of dust at places with high temperatures.
Page 108: Check Before Starting
OPERATION OPERATION 6. Check for problems in handrails, steps, loose bolts. If any problem is found, repair it. Tighten any loose bolts. 7. Check for problems in gauges and monitor Check that there is no problem in the gauges and monitor in the operator's cab. If any problem is found, replace the parts.
Page 109 OPERATION OPERATION 5. When the oil level is higher than H, remove cover (1) in the underpart of the truck. 6. Take the end of hose (2) out of the inspection window. 7. Loosen drain plug (P), drain excess oil and check the oil level again.
Page 110 OPERATION OPERATION CHECK, DRAIN WATER SEPARATOR The water separator serves to separate moisture mixed in the fuel. 1. Open up the engine side cover on the left side of the machine. The water separator is in one piece with fuel pre-filter (1) and located in the lower part.
Page 111 OPERATION OPERATION CHECK COOLANT LEVEL, ADD COOLANT WARNING q Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank. q Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
Page 112 OPERATION OPERATION CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the tem- perature to go down before starting the operation. 1.
Page 113 OPERATION OPERATION CHECK BRAKE PEDAL TRAVEL WARNING If the brake pedal stroke is not 70 to 90 mm (2.8 to 3.5 in) (below 70 mm or over 90 mm), the brake and steering force is too strong or insufficient. If the stroke is 91 mm or longer, adjust it. 1.
Page 114 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand. Fuel is highly flammable and dangerous.
Page 115 OPERATION OPERATION 2. Push the horn switch and check that the horn sounds. CHECK THAT LAMPS LIGHT UP Check that the head lamp, rear lamp, additional working lamp (if equipped), and instrument lamp light up normally and they are free from stain and damage. If the lamps do not light, check for a broken bulb or disconected wire, contact your Komatsu distributor for repairs.
Page 116: Adjustment
OPERATION OPERATION 2. Set the steering, forward-reverse, gear shift lever in the REVERSE position (R). The alarm must sound immediately at this time. The alarm keeps sounding until the steering, forward-reverse, gear shift lever is set to the NEUTRAL position (N) or FOR- WARD position (F).
Page 117 OPERATION OPERATION REMARK The seat can be reclined more when the seat is pushed to the front. The amount of reclining decreases as the seat is pushed back, so when moving the seat back, return the seatback to the upright position. (D) Seat angle adjustment q Front angle adjustment of seat (5 stages) To raise the front of the seat, apply your weight to the seatback, while pulling up lever (4).
Page 118 OPERATION OPERATION FASTENING AND REMOVING SEAT BELT 1. After adjusting the seat position, adjust tether belt (1). Tense the tether belt and install it when there is no one sit- ting on the seat. 2. Sit on the seat and hold tongue (4) connected to wind-in mechanism (2) and pull out the belt slowly so that the belt will cover your abdomen sufficiently.
Page 119 OPERATION OPERATION 1. Pull up lock lever (2) at the rear of console box (1) at the left side of the operator's seat, and set the lock lever to the FREE position. NOTICE Do not grip the steering, forward-reverse, gear shift lever when removing console box (1).
Page 120: Operation And Check Before Starting Engine
OPERATION OPERATION ADJUST ARMREST (LEFT) The height of the armrest on the left side of the operator's seat can be adjusted steplessly up and down 60 mm together with the console box. Turn up/down left adjustment knob (1) to adjust the height. Turn the knob to adjust as follows.
Page 121 OPERATION OPERATION 1. Check that parking brake lever (1) is in the LOCK position (L). REMARK If this parking brake lever is not in the LOCK position, the engine will not start. 2. Check that steering, forward-reverse, gear shift lever (2) is in the NEUTRAL position (N).
Page 122: Starting Engine
OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING q Sit down in the operator's seat before starting the engine. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 123 OPERATION OPERATION 2. Insert the key into starting switch (2) and turn the key to the START position (C). The engine will start. 3. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position (B). 3-69...
Page 124: Starting In Cold Weather
OPERATION OPERATION STARTING IN COLD WEATHER WARNING q Start the engine only after sitting down in the operator's seat. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 125 OPERATION OPERATION 2. Insert the key into starting switch (2) and turn the key to the ON position (B). 3. Check that engine pre-heating pilot lamp (3) on the monitor panel lights up. 4. Maintain the key in the on position until the pre-heating pilot lamp (3) goes off.
Page 126 OPERATION OPERATION REMARK Regardless of the ambient temperature, if the key in starting switch (2) is turned from OFF position to left, preheat- ing pilot lamp (3) will light up and preheating will start. (Preheating continues while the starting switch is held at the left.) For the details of the preheating time, see the table in Step 5.
Page 127: Operations And Checks After Starting Engine
OPERATION OPERATION OPERATIONS AND CHECKS AFTER STARTING ENGINE WARNING q If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position. q If the work equipment is operated without warming the machine up sufficiently, the response of the work equipment to the movement of the control lever will be slow and the work equipment may not respond as the operator desires, so always carry out the warming-up operation.
Page 128: Starting In Cold Weather
OPERATION OPERATION STARTING IN COLD WEATHER (Ambient temperature below 10°C) NOTICE q When the hydraulic oil is at a low temperature, do not carry out operations or move the levers suddenly. Always carry out the warm-up operation. This will help to extend the machine life.
Page 129: Stopping Engine
OPERATION OPERATION 5. After warm-up run is completed, check gauges and caution lamps for proper operation. If any abnormality is found, repair it. q Continue to run the engine at light load until engine coolant temperature gauge indicator (3) and Hydraulic oil temperature gauge (4) fall within the green range (B).
Page 130 OPERATION OPERATION 3. Turn the key in ignition switch (2) to the OFF position (A). The engine will stop REMARK When engine starting switch (2) key is turned to the OFF posi- tion, the engine stops, but the machine's main power source is not turned off immediately.
Page 131: Machine Operation
OPERATION OPERATION MACHINE OPERATION MOVING MACHINE WARNING q When moving the machine, check that the area around the machine is safe, and sound the horn before mov- ing. Do not allow anyone to enter the area around the machine. There is a blind spot at the rear of the machine, so be particularly careful when traveling in reverse.
Page 132 OPERATION OPERATION 3. Put blade control lever (2) in the RAISE position (R) to raise the blade 40 to 50 cm off the ground. 4. Turn fuel control dial (4) to the full speed (MAX) position, and fully depress decelerator pedal (5). 5.
Page 133: Stopping Machine
OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. 1. Depress brake pedal (1) to stop the machine. NOTICE If the brake is depressed when the engine speed or travel speed is high, the brake disc may make a slipping sound. Normally, depress decelerator pedal (2) to reduce the engine speed and travel speed before depressing the brake.
Page 134: Gearshifting Operation
OPERATION OPERATION GEARSHIFTING OPERATION When UP switch (U) or DOWN switch (D) is pushed, the trans- mission speed will change. UP switch (U): Each time the switch is pressed, the transmis- sion will up shift one speed. DOWN switch (D): Each time the switch is pressed, the trans- mission will down shift one speed.
Page 135 OPERATION OPERATION 3. When the preset mode function is actuated, [F1-R1] is dis- played at the left side of the bottom line of display panel B (multi-information) on the monitor panel, and the [F1-R1] mode is set. REMARK When preset mode switch (3) is set to the ON position (a), the default [F1-R1] mode is set.
Page 136: Auto Down Shift Operation
OPERATION OPERATION AUTO DOWN SHIFT OPERATION If the travel speed drops because of the load conditions when traveling, this function automatically down shifts to a lower speed range. 1. The function is actuated when auto shift down switch (4) on the front panel is set to position (ON).
Page 137: Shifting Between Forward And Reverse
OPERATION OPERATION SHIFTING BETWEEN FORWARD AND REVERSE WARNING When switching between FORWARD and REVERSE, first check that the direction of travel is safe. CAUTION The travel direction can be changed without stopping the machine. Do not change it while the engine is running at the full speed, however, but depress the decelerator pedal to lower the engine speed before changing the travel direction for safety, comfort, and longer life of the power...
Page 138 OPERATION OPERATION 4. Release decelerator pedal (1) and raise the engine speed. REMARK If the forward- reverse control lever is shifted when the machine is traveling downhill, a directional change may automatically take place via 1st gear for safety. For example, when the forward- reverse control lever is shifted from F2 to R2, the directional change may take place in the sequence of F2 to R1 to R2.
Page 139: Steering Machine
OPERATION OPERATION STEERING MACHINE WARNING q Avoid as much as possible turning the machine on a slope. The machine will tend to slip sideways. Particular care should be taken on soft or clay soil. q Never make a pivot turn at high speed. NORMAL TURNING WARNING When performing a counterrotation turn, the feeling of operation when your head is facing the rear is dif-...
Page 140: Precautions For Operation
OPERATION OPERATION WHEN MAKING PIVOT TURN TO LEFT WHILE TRAVELING NOTICE When carrying out a counterrotation turn, if the load is not equal on the left and right sides, the machine may carry out a pivot turn, so check the ground conditions and be careful not to hit any obstacles.
Page 141: Precautions On Slopes
OPERATION OPERATION USE ENGINE AS BRAKE When going downhill, move steering, forward-reverse, gear shift lever into low speed to run engine at slow speed and travel down slope using the engine as a brake. Do not move the steering, forward-reverse, gear shift lever to the NEUTRAL position. When traveling down hills of more than 15°, shift down to 1st speed (R1 or F1).
Page 142: Precautions For Blind Spots Caused By Cab And Rops Structures
OPERATION OPERATION PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES (Machine equipped with cab) WARNING The cab structure may cause blind spots. When operating, always be sure to check carefully that there is no obstacle or worker in the surrounding area. WORK POSSIBLE USING BULLDOZER In addition to the following, it is possible to further increase the range of applications by using various attachments.
Page 143: Smoothing
OPERATION OPERATION SMOOTHING NOTICE Avoid smoothing on rocky or stony ground. It can damage the blade. To finish the ground to a flat surface after digging or leveling, put a full load of soil in front of the blade and operate the blade up and down in small movements while traveling forward.
Page 144: Adjusting Posture Of Work Equipment
OPERATION OPERATION ADJUSTING POSTURE OF WORK EQUIPMENT ADJUST ANGLE OF BLADE EDGE WARNING It is dangerous if the work equipment moves by mistake when adjusting angle of the blade edge. Set the work equipment in a stable condition, then stop the engine and lock the work equipment securely with the work equipment lock lever.
Page 145: Adjusting Shims In Assembling Work Equipment
OPERATION OPERATION ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT 1. When assembling the work equipment, adjust an amount of play at each part (C) to the right values shown in the following table. Shim adjusting position Tilt Lift Center Trunnion Item Optimum mm 0.2 - 0.5 0.2 - 0.5...
Page 146: Adjust Amount Of Tilt
OPERATION OPERATION ADJUST AMOUNT OF TILT ANGLEDOZER WARNING When adjusting the amount of tilt, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the work equipment lock lever.
Page 147: Method Of Angling Blade
OPERATION OPERATION METHOD OF ANGLING BLADE Angledozers only When dozing toward one side only, operate with angled blade. WARNING q When adjusting the amount of angling, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the work equipment lock lever.
Page 148: Parking Machine
OPERATION OPERATION PARKING MACHINE WARNING q When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, place the parking brake lever in the LOCK posi- tion and insert blocks underneath the track shoes. As an additional safety measure, thrust the blade into the ground.
Page 149: Check After Finishing Work
OPERATION OPERATION 4. Set work equipment lock leve (3) in the LOCK position (L). CHECK AFTER FINISHING WORK BEFORE STOPPING ENGINE Use the meters and caution lamps to check the engine coolant temperature, engine oil pressure, fuel level, and Power train oil temperature.
Page 150: Locking
OPERATION OPERATION LOCKING To prevent vandalism, there are locks in the following places. Places that can be locked with the starting switch key. q Top cover at front of chassis (1) q Right and left engine side covers (2) q Battery inspection cover (3) q Inspection cover for fuel tank drain valve(4) q Cab door opener (5) (Machine equipped with cab) q Fuel tank filler cap (6)
Page 151: Inspection And Adjustment
OPERATION OPERATION q Do not force the machine to carry out work that exceeds its working capability. Such work includes cases where the idler or sprocket come off the ground when the machine meets obstacles that resist the power of the machine dur- ing dozing or ripping operations.
Page 152 OPERATION OPERATION MEASURING LINK PITCH 1. Insert a wooden block between track shoe and sprocket to take up the slack in track shoes. 2. Measure the pitch length (L) of 4 links at a straight portion at least 2 links from master pin (A). Divide this measure- ment by four to obtain the link pitch.
Page 153 OPERATION OPERATION MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 1. Measure the height (dimension C) of the link tread as shown in the diagram. 2. Stop machine at position where link tread, whose size C has been measured completely, contacts roller tread. Then measure size B.
Page 154: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION MEANS When transporting the machine, choose the optimum transportation method in reference to the weight and dimen- sions shown in “SPECIFICATIONS (5-2)“. Note that machine specifications (weight and dimensions) vary depend- ing on the kind of track shoes and blades.
Page 155: Precautions When Removing Rops
OPERATION TRANSPORTATION 3. Remove right and left trunnions (2). (D65PX,D65WX) REMARK If the machine model is D65PX and D65WX, remove right and left trunnions (2). If the machine model is D65EX, it is not necessary to remove right and left trunnions (2), because the width including them (A) is less than 3.0 m.
Page 156: Loading, Unloading Work
OPERATION TRANSPORTATION LOADING, UNLOADING WORK WARNING q Since loading and unloading of the machine is dangerous, be extremely careful. q When loading or unloading the machine, operate it slowly with the engine speed low and the transmis- sion in the 1st gear. q Use ramps having sufficient width, length, thickness, and strength.
Page 157 OPERATION TRANSPORTATION 4. Set parking brake lever to the FREE position (F). 5. Set the transmission in the 1st gear and run the engine at low idle. 6. Set the travel direction toward the ramps and drive slowly. 7. The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and the machine is unbalanced and becomes dangerous.
Page 158 OPERATION TRANSPORTATION 5. Fix the machine as explained below so that it will not move during transportation. In particular, fix the machine securely to prevent it from slipping sideways. 6. Put blocks (1) in front and behind the track shoes of both sides.
Page 159: Lifting Machine
OPERATION TRANSPORTATION 6. Set parking brake lever to the FREE position (F). 7. Set the transmission in the 1st gear and run the engine at low idle. 8. Set the travel direction toward the ramps and drive slowly. 9. The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and the machine is unbalanced and becomes dangerous.
Page 160 OPERATION TRANSPORTATION PROCEDURE FOR LIFTING OPERATIONS q Hang the front wire ropes to each cylinder support (1) on the right and left sides. q Fit the wire ropes at the rear to both left and the right pivot shafts (2). For machine equipped with ripper q Fit the wire ropes at the center to both left and the right pivot shafts (2).
Page 161: Traveling On Roads
OPERATION TRANSPORTATION 1. Stop the engine and set the parking brake lever to the LOCK position (L) securely. 2. Set the work equipment lock lever to the LOCK position (L) securely. 3. Install wire ropes, slings, etc. matched to the weight of the machine to the lifting points as shown in the above figure.
Page 162: Cold Weather Operation
OPERATION COLD WEATHER OPERATION COLD WEATHER OPERATION PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as fol- lows. FUEL AND LUBRICANTS Change to oil with low viscosity for all components. For details of the specified visicosity, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (4-12)“.
Page 163: After Completion Of Work
OPERATION COLD WEATHER OPERATION When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%. Insulate it against cold temperature to ensure the machine can be started easily the next morning.
Page 164: Long-Term Storage
OPERATION LONG-TERM STORAGE LONG-TERM STORAGE BEFORE STORAGE When keeping in long-term storage (more than one month), store as follows. q Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level ground and cover the machine with a sheet. q Completely fill the fuel tank.
Page 165: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. PROCEDURE FOR BLEEDING AIR 1. Insert the key into the engine starting switch and turn the key to ON position (B).
Page 166: Method Of Towing Machine
OPERATION TROUBLESHOOTING METHOD OF TOWING MACHINE WARNING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. If the engine does not start, put blocks under the track to prevent the machine from moving, then release the brake.
Page 167: If Battery Is Discharged
OPERATION TROUBLESHOOTING If the machine gets stuck in the mud or a heavy thing needs to be towed, install a towing wire rope to the draw bar pin. q Connect a wire rope to the part indicated with the arrow in the diagram at right.
Page 168: Remove And Install Battery
OPERATION TROUBLESHOOTING REMOVE AND INSTALL BATTERY 1. Open the battery cover. 2. Before removing battery, remove the ground cable (normally connected to the negetive (-) terminal). If any tool touches between the positive terminal and the chassis, there is danger of sparks being generated. Loosen the nuts of the terminal and remove the wires from the battery.
Page 169: Starting Engine With Booster Cable
OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING q When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. q When starting the engine with a booster cable, wear safety glasses and rubber gloves.
Page 170 OPERATION TROUBLESHOOTING CONNECTING THE BOOSTER CABLE Keep the starting switch of the normal machine and problem machine in the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Connect the clip of booster cable (A) to the positive (+) ter- minal of battery (C) on the problem machine.
Page 171: Other Trouble
OPERATION TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main cause Remedy •Defective wiring (•Check, repair loose terminals, dis-...
Page 172: Monitor Panel
OPERATION TROUBLESHOOTING MONITOR PANEL When an error code appears on the display panel B (multi- information), take appropriate remedies based upon the table below. (1): Display panel B (2): Warning lamp (red) REMARK If different kinds of failures occur at the same time, their failure codes are arranged in the order of seriousness in the display.
Page 173: Chassis
OPERATION TROUBLESHOOTING CHASSIS q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy •Improper tightening of oil pipe, •Check, repair pipe joint, air leaking in or oil leaking out because of...
Page 174 OPERATION TROUBLESHOOTING Problem Main causes Remedy •Lack of hydraulic oil •Add oil to specified level. For details, see EVERY 250 HOURS Blade rises too slowly or does not SERVICE rise at all •Defective hydraulic pump •Check (or blade tilts too slowly) •Work equipment lock lever is in •Set to FREE position LOCK position...
Page 175: Engine
OPERATION TROUBLESHOOTING ENGINE q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy •Add oil to specified level, see •Engine oil pan oil level is low (suck- CHECK BEFORE STARTING ing in air)
Page 176 OPERATION TROUBLESHOOTING Problem Main causes Remedy Monitor displays error code Alarm buzzer sounds Please contact your Komatsu distributor Engine horsepower lowered sud- denly (Engine is running in duration mode) 3-122...
Page 177 OPERATION TROUBLESHOOTING 3-123...
Page 178 OPERATION TROUBLESHOOTING 3-124...
Page 179: Maintenance
MAINTENANCE WARNING Please read and make sure that you understand the SAFETY section before reading this section.
Page 180: Guide To Maintenance
MAINTENANCE GUIDE TO MAINTENANCE GUIDE TO MAINTENANCE Do not perform any inspection and maintenance operation that is not found in this manual. CHECK SERVICE METER: Check the service meter reading every day to see if the time has come for any necessary maintenance to be per- formed.
Page 181 MAINTENANCE GUIDE TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: q Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged. q Clean the radiator core frequently to avoid clogging. q Clean and replace the fuel filter frequently. q Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Page 182 MAINTENANCE GUIDE TO MAINTENANCE PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES: q When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and replace with new parts. When doing this, be careful not to forget to assemble the O-rings and gaskets. q When installing the hoses, do not twist them or bend them sharply.
Page 183: Outline Of Service
MAINTENANCE OUTLINE OF SERVICE OUTLINE OF SERVICE q Always use Komatsu genuine parts for replacement parts, grease or oil. q When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the old oil and fill completely with the new oil.
Page 184: Fuel
MAINTENANCE OUTLINE OF SERVICE FUEL q To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day's work. q The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly. q Be extremely careful not to let impurities get in when storing or adding fuel.
Page 185: Grease
MAINTENANCE OUTLINE OF SERVICE GREASE q Grease is used to prevent seizure and noises at the joints. q This construction equipment is used under heavy-duty conditions. Always use the recommended grease and follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 186: Storing Oil And Fuel
MAINTENANCE OUTLINE OF SERVICE OIL SAMPLING q Sampling interval 250 hours: Engine 500 hours: Other components q Precautions when sampling q Make sure that the oil is well mixed before sampling. q Perform sampling at regular fixed intervals. q Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor.
Page 187: Handling Hydraulic System
MAINTENANCE OUTLINE OF SERVICE q Be careful to keep the electric system free of water when washing the machine or when it rains. q When working at the seashore, carefully clean the electric system to prevent corrosion. q When installing electrical equipment, connect it to the special power source connector. Do not connect the optional power source to the fuse, starting switch, or battery relay.
Page 188: Wear Parts List
MAINTENANCE WEAR PARTS LIST WEAR PARTS LIST Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of the machine.
Page 189 MAINTENANCE WEAR PARTS LIST Replacement Item Part No. Part Name Weight (kg) Q'ty frequency 37.5 130-70-41130 Cutting edge (right) 34.0 130-920-2180 Cutting edge (left) (02090-11270) (Bolt) (17) D65EX (02290-11219) (Nut) (17) Semi-U blade 175-71-22272 End bit (left) 39.0 (tilt dozer) 175-71-22282 End bit (right) 39.0...
Page 190: Recommended Fuel, Coolant, And Lubricant
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT q Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 191: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE AMBIENT Recommended Komatsu Genuine TEMPERATURE Reservoir Fluid type Fluids SAE0W30EOS and HTHS Over 3.5cP. -30°C 30°C (Note.1) Komatsu EOS0W30 SAE5W40EOS and HTHS Over 3.5cP. -25°C 40°C (Note.1)
Page 192 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT Final drive Cooling Power Engine Damper Idler Hydraulic case (each) Fuel system train oil pan case (each) system tank (including case PX,WX sub-tank) Specified Liters 0.15 capacity Refill Liters 0.15 capacity NOTICE Use only diesel fuel. The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel consumption and good exhaust gas characteristics.
Page 193: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifica- tions, refer to the Komatsu web page or consult your Komatsu distributor. 4-15...
Page 194: Standard Tightening Torques For Bolts And Nuts
MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS TORQUE LIST CAUTION If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and this will cause failure of the machine or problems with operation. Always pay careful attention when tightening parts.
Page 195: Periodic Replacement Of Safety Critical Parts
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, the parts in the safety-critical parts list on the next page must also be replaced at the specified interval.
Page 196 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS NO. Safety critical parts for periodic replacement Q'ty Replacement interval Hose (main valve - central drain block) Hose (main control valve - blade tilt relay block) Hose (blade tilt relay block - Tilt cylinder) Hose (main valve - blade tilt relay tube) Hose (Radiator guard upper part - Lift cylinder) Hose (self-reducing pressure valve - fan pump)
Page 197: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ................4-214 CLEAN INSIDE OF COOLING SYSTEM......................4-244 CHECK TRACK SHOE TENSION, ADJUST ....................4-274 CHECK AND TIGHTEN TRACK SHOE BOLTS ....................4-294 REVERSE AND REPLACE END BITS AND CUTTING EDGES..............
Page 198: Every 2000 Hours Service
MAINTENANCE MAINTENANCE SCHEDULE CHART CHANGE OIL IN FINAL DRIVE CASE ......................4-634 CLEAN BREATHER............................4-634 REPLACE CORROSION RESISTOR CARTRIDGE..................4-644 CHECK FOR LOOSE ROPS MOUNT BOLTS ....................4-644 INSPECTION OF AFTER-COOLER CIRCUIT FOR LOOSENED BOLTS AND NUTS........4-644 EVERY 2000 HOURS SERVICE CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT ............
Page 199: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING q If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. q When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 200 MAINTENANCE SERVICE PROCEDURE 4. Clean the interior of the air cleaner body, cover (3) and evacuator valve (6). NOTICE The inner element must not be used again even after cleaning. When replacing the outer element, replace the inner element at the same time. 5.
Page 201 MAINTENANCE SERVICE PROCEDURE 11. Push the button of dust indicator (1) and return the yellow piston to its original position. 12. Close the left engine side cover. REPLACING ELEMENT 1. Open the left engine side cover. 2. Remove three clips (2), then remove cover (3). 3.
Page 202: Clean Inside Of Cooling System
MAINTENANCE SERVICE PROCEDURE 7. Replace O-ring (7) for cover (3) with new one. 8. Set the arrow mark on cover (3) at the top, install to the air cleaner body, then secure with clip (2). 9. Push the button of dust indicator (1) and return the yellow piston to its original position.
Page 203 MAINTENANCE SERVICE PROCEDURE The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 204 MAINTENANCE SERVICE PROCEDURE 2. Turn radiator cap (1) slowly until it hits the stopper and by so doing, relieving the internal pressure. 3. Turn radiator cap (1) until it hits the next stopper, while depressing it. Keep turning the radiator cap (1) until it hits the last stopper.
Page 205: Check Track Shoe Tension, Adjust
MAINTENANCE SERVICE PROCEDURE 12. Drain the coolant from sub-tank (4), clean the inside of the sub-tank, then add water until the coolant level is between the FULL and LOW marks. 13. Stop the engine, wait for approx. 3 minutes, then add cool- ant until the coolant level is near the coolant filler port, and tighten the cap.
Page 206 MAINTENANCE SERVICE PROCEDURE WHEN INCREASING TENSION Prepare a grease pump. 1. Pump in grease through grease fitting (2) with a grease pump. 2. To check that the correct tension has been achieved, move the machine backwards and forwards. 3. Check the track tension again, and if the tension is not cor- rect, adjust it again.
Page 207: Check And Tighten Track Shoe Bolts
MAINTENANCE SERVICE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. METHOD OF TIGHTENING (TRACK SHOE BOLTS) 1. Torque the track shoe bolts to 539 ± 49 N·m (55 ± 5 kg·m). Then ensure the nut and shoes are in close contact with the link contact surface.
Page 208: Reverse And Replace End Bits And Cutting Edges
MAINTENANCE SERVICE PROCEDURE REVERSE AND REPLACE END BITS AND CUTTING EDGES WARNING It is dangerous if the work equipment moves during the turning or replacement operation. Set the work equipment in a stable condition, set the work equipment lock lever to the LOCK position, then stop the engine.
Page 209 MAINTENANCE SERVICE PROCEDURE 5. Reverse or replace the cutting edge and the end bit when worn out. 6. Remove nut (1) and bolt (2), then replace or reverse the cutting edge and the end bit. 7. Install the cutting edge on the blade and tighten the bolt temporarily.
Page 210: Cleaning And Inspection Of Fins Of Radiator, Oil Cooler, Condenser And After-Cooler
MAINTENANCE SERVICE PROCEDURE CLEANING AND INSPECTION OF FINS OF RADIATOR, OIL COOLER, CONDENSER AND AFTER-COOLER If the radiator fins are clogged or dirty, clean and inspect them. CLEANING BY COOLING FAN REVERSE TURN NOTICE q When turning the cooling fan in the reverse direction, be careful of dirt that is sent flying around.
Page 211 MAINTENANCE SERVICE PROCEDURE 6. After completing the cleaning, run the engine at low idle for approx. 10 seconds. 7. Turn starting switch (1) to the OFF position and stop the engine. 8. Turn starting switch (1) to the ON position. 9.
Page 212 MAINTENANCE SERVICE PROCEDURE CLEANING OF OIL COOLER FINS AND CONDENSER FINS When the oil cooler fins and condenser fins are clogged or lots of dust is accumulated, clean them with com- pressed air. 1. Open up right and left side covers (1). 2.
Page 213: Check, Adjust Air Conditioner
MAINTENANCE SERVICE PROCEDURE 6. Remove right and left bolts (11) - 2 bolts in total, and loosen bolts (12) - 2 bolts in total - to swing back oil cooler (9) and air conditioner condenser (10). 7. Blow off dirt, dust and dry leaf shreds clogging the oil cooler fins and air conditioner condenser fins with com- pressed air.
Page 214: Grease Door Hinge
MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF REFRIGERANT WARNING If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit. Do not bring any flame close to any point where the refrigerant gas is leaking.
Page 215: Check Door Lock Striker
MAINTENANCE SERVICE PROCEDURE CHECK DOOR LOCK STRIKER (Machine equipped with cab) If wear (A) of the door of lock striker exceeds 0.5 mm, replace the striker. If it is used as it is, the play will increase and this may result in breakage of the hinge or door lock. REPLACE DOOR DAMPER (Machine equipped with cab) If depth (A) of the groove of door damper rubber (1) is less than...
Page 216: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE SERVICE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab) If there is air in the window washer fluid, check the level and add fluid. Open the engine side cover on the right side, check the level of the fluid in window washer tank(1), and if it is low, add automo- bile window washer fluid.
Page 217: Replace Wiper Blade
MAINTENANCE SERVICE PROCEDURE REPLACE WIPER BLADE (Machine equipped with cab) If the blade is damaged, it will not wipe the window clean, so replace the blade. REPLACEMENT FRONT, DOOR WIPER 1. It is hooked at portion (A), so move the blade in the direc- tion of the arrow to remove it.
Page 218: Check Idler Oil Level, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK IDLER OIL LEVEL, ADD OIL WARNING If the oil level in the idler is low, new oil must be added, and the machine body must be inclined in this case. Since this work is dangerous, ask your Komatsu distributor. If the oil level in the idler is low, noise will be generated and there will be seizure, so check the oil level and add oil as follows.
Page 219: Lubricating Universal Joint
MAINTENANCE SERVICE PROCEDURE ADJUSTMENT 1. Travel for 1 or 2 meters on flat ground, then measure clear- ance (A) between track frame (1) and guide plate (2) (4 places: left, right, inside, outside). 2. If the clearance (A) exceeds 4.0 mm, loosen bolt (3), and pull out the shim to adjust the clearance at one end to 0.5 to 1.0 mm.
Page 220: Procedure For Bleeding Air In Hydraulic System
MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM See “STARTING ENGINE (3-68)“. Since the engine must be started and the blade must be operated, see OPERATION. NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing.
Page 221: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see “CHECK BEFORE STARTING (3-54)“ in the OPERATION section. q Check oil level in engine oil pan, add oil q Check dust indicator q Check, drain water separator q Check coolant level, add coolant q Check oil level in power train case, add oil q Check electric wiring...
Page 222: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATING 1. Lower the blade to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 223: Grease Equalizer Bar Side Pin
MAINTENANCE SERVICE PROCEDURE (3) Lift cylinder ball joint (2 places) (4) Tilt cylinder ball joint (1 place) (5) Pitch cylinder ball joint (1 place) (6) Brace ball joint (2 places) ANGLEDOZER (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 (2 places) (5) Tilt brace thread (2 places)
Page 224: Grease Equalizer Bar Center Pin
MAINTENANCE SERVICE PROCEDURE GREASE EQUALIZER BAR CENTER PIN (1 place) 1. Open the engine side cover on the left side of the chassis. 2. Clean the grease fitting indicated with the arrow, then sup- ply grease to that fitting with a grease pump. CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING q The oil is at high temperature immediately after the machine has been operated.
Page 225: Check Oil Level In Hydraulic Tank, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 226: Check Level Of Battery Electrolyte
MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Perform this check before operating the machine. WARNING q Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will acceler- ate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion.
Page 227: Check, Clean Additional Fuel Strainer
MAINTENANCE SERVICE PROCEDURE WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows. 1.
Page 228: Check Brake Performance
MAINTENANCE SERVICE PROCEDURE CHECK BRAKE PERFORMANCE WARNING If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately. NOTICE Do not place the gear shift lever in 1st under any circumstances. The machine will be damaged. Before starting the engine, check that the area around the machine is safe, then do as follows: 1.
Page 229: Clean Air Conditioner Air Filter (Fresh/Recirc Filter)
MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (Machine equipped with cab) Clean the air conditioner air filter if it becomes clogged or if there is dirt or oil stuck to it. In places where there is a lot of dust, clean the air filter once a week. In addition, clean the air conditioner air filter at the same time, when cleaning the engine air cleaner.
Page 230: Every 500 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 500 HOURS SERVICE Maintenance for every 50 and 250 hours service should be carried out at the same time. CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns.
Page 231 MAINTENANCE SERVICE PROCEDURE 8. Remove bolts (5) - 4 bolts in total - to remove washer tank assembly (6). 9. Turn engine oil filter cartridge (7) to the left with a filter wrench. 10. Clean the filter holder, fill the new filter cartridge with clean oil, coat the thread and packing portion of the new filter car- tridge with oil (or coat thinly with grease), then install.
Page 232: Replace Power Train Oil Filter Element
MAINTENANCE SERVICE PROCEDURE REPLACE POWER TRAIN OIL FILTER ELEMENT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. 1. Open cover on the right side of the machine. 2.
Page 233 MAINTENANCE SERVICE PROCEDURE Prepare a filter wrench and a container to catch the fuel. 1. Open the inspection cover at the bottom of the fuel tank. 2. Close fuel tank valve (1). 3. Open up the engine side cover on the left side of the machine.
Page 234 MAINTENANCE SERVICE PROCEDURE 12. Connect connector (2) to the water separator. 13. Open fuel tank valve (1). 14. Bleed air from fuel filter cartridge (4) after the replacement. Bleed the air as follows: 15. Insert the key into the engine starting switch and turn the key to ON position (B).
Page 235: Every 1000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 50, 250 and 500 hours should be carried out at the same time. REPLACE FUEL MAIN FILTER CARTRIDGE Carry out this operation after carrying out the maintenance in the “REPLACE FUEL PRE-FILTER CARTRIDGE (4- 54)“...
Page 236 MAINTENANCE SERVICE PROCEDURE 3. Open up the engine side cover on the left side of the machine. 4. Remove bolts (2) - 2 bolts in total- to remove lower side cover (3). 5. Put a container under filter cartridge (4) to receive drained oil.
Page 237 MAINTENANCE SERVICE PROCEDURE 11. Insert the key into the engine starting switch and turn the key to ON position (B). Then the electric priming pump begins to work. 12. After holding the key in ON position (B) for 30 seconds, turn it back to OFF position (A) and hold it there for 10 sec- onds.
Page 238: Change Oil In Power Train Case, Clean Strainers (Power Train Pump Strainer, Scavenging Pump Strainer)
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER) WARNING q The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. q The undercover is heavy.
Page 239 MAINTENANCE SERVICE PROCEDURE 7. Loosen mounting bolt (4) of the power train strainer, then remove cover (5). 8. Take out spring (6), then take out strainer (7). 9. Remove all dirt from strainer (7), then wash in clean diesel oil or flushing oil. Clean the case interior and the removed parts.
Page 240: Check Oil Level In Damper Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN DAMPER CASE, ADD OIL WARNING q The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. q The undercover is heavy. Never try to open or close the cover when directly beneath it.
Page 241: Change Oil In Final Drive Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN FINAL DRIVE CASE WARNING q The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. q If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.
Page 242: Replace Corrosion Resistor Cartridge
MAINTENANCE SERVICE PROCEDURE REPLACE CORROSION RESISTOR CARTRIDGE Use Komatsu genuine cartridge. 1. Screw in 2 valves (1) at the top of the corrosion resistor. 2. Using a filter wrench, turn cartridge (2) to the left to remove 3. Apply engine oil to the sealing surface of a new cartridge, then install it to the filter holder.
Page 243: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Page 244: Replace Hydraulic Tank Breather Element
MAINTENANCE SERVICE PROCEDURE REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 245 MAINTENANCE SERVICE PROCEDURE FUNCTION OF ACCUMULATOR The accumulator stores the pressure in the control circuit. Even after the engine is stopped, the control circuit can be operated, so the following actions are possible. q If the control lever is operated in the direction to lower the work equipment, it is possible for the work equipment to go down under its own weight.
Page 246 MAINTENANCE SERVICE PROCEDURE 4. While holding the work equipment at the highest position, turn the engine starting switch key to OFF position (A). 5. Turn the engine starting switch key to ON position (B). 6. Turn the work equipment lock lever to FREE position (F). 7.
Page 247: Change Oil In Damper Case
MAINTENANCE SERVICE PROCEDURE METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT NOTICE Finish the steps of operating the blade control lever to the front and back, and to the right and left, to each stroke end within 15 seconds after the engine has stopped. After the engine stops, pressure inside the accumulator begins to gradually go down, so the pressure cannot be released except right after the engine stops.
Page 248: Check Vibration Damper
MAINTENANCE SERVICE PROCEDURE 5. Remove oil level plug (3) and oil filler plug (4), then remove drain plug (5) to drain the oil. After the all oil is drained, tighten plug (5). 6. Add oil through the hole of oil filler plug (4) until the oil level reaches the bottom edge of the hole of oil level plug (3).
Page 249: Every 4000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 4000 HOURS SERVICE Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be carried out at the same time. REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) Replace the accumulator every 2 years or every 4000 hours, whichever comes sooner. WARNING The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explo- sion, which will lead to serious injury or damage.
Page 250: Checking For Looseness Of High-Pressure Clamp, Hardening Of Rubber
MAINTENANCE SERVICE PROCEDURE CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER Check clamp (1) visually or with a finger to see if there is any loosed bolt, or the rubber portion is hardened. If any such abnormality is found, call on your Komatsu distributor for repairs or replacement.
Page 251: Checking For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
MAINTENANCE SERVICE PROCEDURE CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER Check fuel spray prevention caps (1) through (14) visually or with a finger to see if any of them has slipped off, or the rubber portion is hardened. If any such abnormality is found, call on your Komatsu distributor for repairs or replacement.
Page 252: Every 8000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 8000 HOURS SERVICE Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Contact your Komatsu distributor to have the engine high-pressure clamps replaced. REPLACE FUEL SPLAY PREVENTION CAPS Contact your Komatsu distributor to have the fuel spray prevention cap replaced.
Page 253: Specifications
SPECIFICATIONS...
Page 254 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS D65EX and D65WX: Semi-U dozer with ROPS guard, cab and air conditioner D65PX: Power tilt-dozer with ROPS guard, cab and air conditioner Item Unit D65EX-15 D65PX-15 D65WX-15 Machine weight 20,280 21,000 21,140 Name of engine Komatsu SAA6D114E-3 diesel engine Engine horsepower (ISO9249) kw{HP}/rpm 153{205}/1,950...
Page 255: Attachments, Options
ATTACHMENTS, OPTIONS WARNING Please read and make sure that you understand the safety section before reading this section.
Page 256: General Precautions
ATTACHMENTS, OPTIONS GENERAL PRECAUTIONS GENERAL PRECAUTIONS PRECAUTIONS RELATED TO SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distribu- tor first.
Page 257: Handling Hydraulic Ripper
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER HANDLING HYDRAULIC RIPPER q This hydraulic ripper is for D65EX and D65WX dozers. GENERAL VIEW Hydraulic cylider Shank Link Point Beam Support...
Page 258: Explanation Of Components
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER WARNING When carrying out inspection or maintenance of the machine, or when parking the machine, lower the rip- per to the ground and set the work equipment lock lever to the LOCK position. This lever is used to operate the ripper.
Page 259: Operation
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER OPERATION CHECK BEFORE STARTING ENGINE, ADJUST WALK-AROUND CHECK 1. Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the rivets. If any problem is found, replace or repair. PRECAUTIONS WHEN OPERATING q Travel in low speed and lower the ripper gradually when starting to move the machine off.
Page 260 ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER When changing the digging depth, do as follows. 1. Remove cotter pin (1). 2. Remove pin (2), change the position of the shank hole, then insert pin (2). 3. Insert cotter pin (1). ADJUSTING DIGGING ANGLE Adjust the position of the mounting pin hole in the beam and upper link.
Page 261: Troubleshooting
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER TROUBLESHOOTING OTHER TROUBLE q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Slow ripper raising and function,...
Page 262: Specifications
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER (1) Ripper cylinder foot pin (1 place) (2) Ripper cylinder rod end pin (1 place) (3) Link pin (8 places) CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL 1. Stop the machine on level ground. Set the blade perpendicular and lower it the ground, lower the ripper to the ground, then stop the engine.
Page 263: Air Suspension Seat
ATTACHMENTS, OPTIONS AIR SUSPENSION SEAT AIR SUSPENSION SEAT ADJUSTMENT WARNING When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK position to prevent any accidental contact with the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 264 ATTACHMENTS, OPTIONS AIR SUSPENSION SEAT If the operator raises his body from the seat or changes the amount of weight applied to the seat during adjust- ment, the air in the suspension may be discharged. Amount of adjustment: 80 mm After the automatic weight adjustment is carried out, the seat height is at the lowest point in the adjustment range.
Page 265 ATTACHMENTS, OPTIONS AIR SUSPENSION SEAT (H) Adjusting headrest height Move the headrest up or down and set to the desired height. Amount of adjustment: 100 mm (I) Lumbar support Operate switch (6) to give a suitable tension to the lumbar region. When + is pressed: Tension becomes stronger When - is pressed: Tension becomes weaker Adjust the backrest to the desired curve.
Page 266: Deluxe Seat
ATTACHMENTS, OPTIONS DELUXE SEAT DELUXE SEAT (Rotating seat) ADJUSTMENT WARNING When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK position to prevent any accidental contact with the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 267 ATTACHMENTS, OPTIONS DELUXE SEAT (D) Adjusting direction of seat NOTICE Depending on the position of the seat, when changing the direction of the seat, it may contact the console or other parts. Be extremely careful. Pull up lever (5) to unlock the seat. The seat can then be turned 15°...
Page 268: Headrest
ATTACHMENTS, OPTIONS HEADREST HEADREST Removal of headrest Pull up the headrest. REMARK The headrest cannot be fixed to halfway. 6-14...
Page 269: Equipping Fire Extinguisher And First-Aid Kit
ATTACHMENTS, OPTIONS EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT Equipping the fire extinguisher and the first-aid kit at the illustrated position needs brackets (if equipped). The fire extinguisher and the first-aid kit can be installed to the positions shown in the following illustration. (1) First Aid Kit (2) Fire Extinguisher For information on parts which are required to install these...
Page 270 ATTACHMENTS, OPTIONS EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT 6-16...
Page 271 INDEX...
Page 272 INDEX...
Page 273 INDEX INDEX <A> GUIDE TO MAINTENANCE ........4-2 ADJUSTING POSTURE OF WORK EQUIPMENT.. 3- <H> AIR CONDITIONER, HANDLING ......3-48 HANDLING HYDRAULIC RIPPER ......6-3 GENERAL LOCATIONS AND FUNCTION OF EXPLANATION OF COMPONENTS ....6-4 CONTROL PANEL .......... 3-48 GENERAL VIEW..........6-3 METHOD OF OPERATION......
Page 274 INDEX OPERATIONS AND CHECKS AFTER STARTING <T> ENGINE ............3-73 TIPS FOR LONGER UND ........3-96 OUTLINE OF SERVICE .........4-5 TOOL BOX ............3-47 TORQUE LIST ............. 4-16 TRANSPORTATION.......... 3-100 <P> TRANSPORTATION MEANS ......3-100 PARKING MACHINE ...........3-94 TRAVELING ON ROADS ........3-107 PERIODIC REPLACEMENT OF SAFETY CRITICAL TROUBLESHOOTING........
Page 275 COLOPHON...

This manual is also suitable for:

D65px-15e0 69001

Komatsu Utility D65EX-15E0 Operation & Maintenance Manual

Foreword

Before Reading this Manual

Important Safety Information

Intended Use

Location of Plates, Table to Enter Serial No. and Distributor

Safety

Important Safety Information

Safety Labels

Precautions Common to Operation and Maintenance

Precautions During Operation

Precautions for Maintenance

Precautions for Machine

Operation

General View

Contents

Explanation of Components

Operation

Transportation

Contents

Cold Weather Operation

Long-Term Storage

Troubleshooting

Maintenance

Guide to Maintenance

Outline of Service

Wear Parts List

Recommended Fuel, Coolant, and Lubricant

Standard Tightening Torques for Bolts and Nuts

Periodic Replacement of Safety Critical Parts

Maintenance Schedule Chart

Service Procedure

Contents

Quick Links

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Komatsu Utility D65EX-15E0