Page 1 Operation & EEAM023402 Maintenance Manual D155AX BULLDOZER SERIAL NUMBER D155AX - 76243 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. This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine.
Page 3 FOREWORD...
Page 4 FOREWORD FOREWORD FOREWORD This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre- cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci- dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
Page 5 FOREWORD FOREWORD q Machine equipped without cab Back pocket of operator's seat...
Page 6: Foreword
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa- tions.
Page 7 FOREWORD SAFETY INFORMATION q Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to indicate safety procedures. Example of safety label using words Part No.
Page 8: Noise Emission Levels
FOREWORD 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 9: Guide To Reduce Vibration Levels On Machine
FOREWORD SAFETY INFORMATION (TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion (Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading, and travelling without load) Guide to Reduce Vibration Levels on Machine The following guides can help an operator of this machine to reduce the whole body vibration levels: 1.
Page 10: Introduction
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: q Dozing q Cutting into hard or frozen ground or ditching q Felling trees, removing stumps q Pushing q Ripping For further details, see “WORK POSSIBLE USING BULLDOZER (3-118)“ and “RIPPER OPERATION (3-111)“. FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE Front Right...
Page 11: Breaking In The Machine
FOREWORD INTRODUCTION BREAKING IN THE 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. Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Page 12: Necessary Information
FOREWORD NECESSARY INFORMATION NECESSARY INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE Under the front of the console box on the right side of the operator's seat. The design of the nameplate differs according to the territory.
Page 13: Engine Serial No. Plate And Position (2)
FOREWORD NECESSARY INFORMATION ENGINE SERIAL NO. PLATE AND POSITION (2) q This is the same content as engine serial No. plate (1). q Located on the top of the air cleaner mounting bracket on the left of the machine. q This also acts as the EPA plate. EPA: Environmental Protection Agency, U.S.A.
Page 14: Ripper Serial No. Plate Position
FOREWORD NECESSARY INFORMATION RIPPER SERIAL NO. PLATE POSITION This is located on the left side surface of ripper beam. ROPS, FOPS NO. PLATE POSITION This is located on the top left. ROPS FOPS POSITION OF SERVICE METER On top of the machine monitor 1-12...
Page 15 FOREWORD NECESSARY INFORMATION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product Identification Number Manufacturers name: KOMATSU LTD. Address: 3-6 Akasaka Minato-ku, 101 Tokyo Japan Distributor Address Phone Service personnel for your machine: MACHINE SERIAL NUMBER PLATE Model Seriel Number Manufacturing year...
Page 16 FOREWORD NECESSARY INFORMATION 1-14...
Page 17 FOREWORD NECESSARY INFORMATION 1-15...
Page 18: Table Of Contents
CONTENTS CONTENTS FOREWORD FOREWORD ................................. 1-2 SAFETY INFORMATION............................1-4 Noise emission levels ..........................1-6 Vibration levels............................1-6 Guide to Reduce Vibration Levels on Machine.................. 1-7 INTRODUCTION..............................1-8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE ............... 1-8 BREAKING IN THE MACHINE ........................1-9 NECESSARY INFORMATION ...........................
Page 19 CONTENTS OPERATION GENERAL VIEW ..............................3-2 GENERAL VIEW OF MACHINE ......................... 3-2 GENERAL VIEW OF CONTROLS AND GAUGES..................3-3 EXPLANATION OF COMPONENTS........................3-5 FRONT PANEL............................3-5 CHECK MONITOR GROUP ......................3-7 CAUTION MONITOR GROUP ......................3-9 EMERGENCY CAUTION ITEMS ....................3-11 METER GROUP ..........................
Page 20 CONTENTS ACCUMULATOR ..........................3-68 OPERATION ............................... 3-69 CHECK BEFORE STARTING ENGINE, ADJUST..................3-69 WALK-AROUND CHECK ........................ 3-69 CHECK BEFORE STARTING ......................3-71 ADJUSTMENT..........................3-82 OPERATIONS AND CHECKS BEFORE STARTING ENGINE ............3-86 STARTING ENGINE ..........................3-88 NORMAL STARTING ........................3-88 STARTING IN COLD WEATHER ....................
Page 21 CONTENTS DOZING............................3-118 SMOOTHING..........................3-118 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING ..........3-119 FELLING TREES, REMOVING STUMPS ..................3-119 PUSHER OPERATIONS ....................... 3-119 ADJUSTING POSTURE OF WORK EQUIPMENT................. 3-120 METHOD OF ANGLING BLADE ....................3-120 ADJUSTING TILT AMOUNT ......................3-122 ADJUSTING RIPPER ........................
Page 22 CONTENTS MAINTENANCE GUIDES TO MAINTENANCE ..........................4-2 OUTLINES OF SERVICE ............................. 4-5 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC............4-5 OIL ..............................4-5 FUEL..............................4-6 COOLANT AND WATER FOR DILUTION..................4-6 GREASE ............................4-6 CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ..............4-7 STORING OIL AND FUEL .........................
Page 23 CONTENTS EVERY 4000 HOURS SERVICE ......................4-75 EVERY 8000 HOURS SERVICE ......................4-78 SPECIFICATIONS SPECIFICATIONS ..............................5-2 ATTACHMENTS, OPTIONS GENERAL PRECAUTIONS ..........................6-2 PRECAUTIONS RELATED TO SAFETY ....................6-2 INTRODUCTION OF ATTACHMENTS AND OPTIONS ..................6-3 INTRODUCTION OF ATTACHMENTS AND OPTIONS................6-3 HEADREST, HANDLING .............................
Page 24 CONTENTS 1-22...
Page 25: Safety
SAFETY WARNING Please be sure that you fully understand this manual and the precautions discribed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precaustions strictly.
Page 26 SAFETY SAFETY SAFETY Safety Labels ..............................2-42 Positions of Safety Pictograms ........................2-42 Safety Labels ............................. 2-112 General Precautions Safety Rules............................... 2-112 If Abnormalities are Found ......................... 2-112 Clothing and Personal Protective Items ..................... 2-112 Fire Extinguisher and First Aid Kit......................2-112 Safety Features............................
Page 27 SAFETY SAFETY Precautions for Operation ..........................2-202 Before Starting Engine..........................2-202 Checks Before Starting Engine......................2-202 Precautions when Starting ........................2-202 Precautions in Cold Areas ........................2-212 Operation ..............................2-222 Checks Before Operation........................2-222 Precautions for Moving Machine Forward or in Reverse ..............2-222 Precautions when Traveling........................
Page 28: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS POSITIONS OF SAFETY PICTOGRAMS...
Page 29: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Precautions for operation, inspection, and maintenance (09651-A0641) q Warning! q Read manual before operation, maintaince, disassembly, assembly and transportation. (2) Precautions when traveling in reverse (09802-13000) WARNING To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments: q Honk horn to alert people nearby.
Page 30 SAFETY SAFETY LABELS (4) Warning for hot water hazard (09653-A0481) q Never remove the cap when the engine is at operating (High) temperature. Stream or high temperature oil blowing up from the radiator or hydraulic tank, will cause personal injury and / or burns. q Never remove the radiator or hydraulic tank oil filler when cooling water or hydraulic oil is at high temperatures.
Page 31 SAFETY SAFETY LABELS (8) Precautions when handling cable (09808-A0881) q There is the hazard to electric shock when handling electric wires. q Read the operation and maintenance manual and carrying out the correct method when handling. (9) Caution against falling (09805-C0881) q Sign indicates a hazard of falling q Do not stand on this place here (10) Caution to stop engine when carrying out inspection and...
Page 32 SAFETY SAFETY LABELS (11) Caution about going close when machine is moving (09806-B1683) q Sign indicates a hazard of being run over by moving equip- ment. q Keep a safe distance from equipment when it is moving. (12) Caution for high voltage (7872-10-1600) There is a danger of electrocution.
Page 33 SAFETY SAFETY LABELS (14) ROPS (09620-B2000) ROPS CERTIFICATION This protective structure complies with the standard provided that is properly equipped on the machine which mass is less than the specified maximum mass. 1. MODEL 3. FOPS LEVEL No. 5. MAX. MASS kg (Lb) 2.
Page 34 SAFETY SAFETY LABELS (15) 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 35: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES q Only trained and authorized personnel can operate and maintain the machine. q Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
Page 36 SAFETY GENERAL PRECAUTIONS SAFETY FEATURES q Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. q Understand the method of use of safety features and use them properly. q Never remove any safety features.
Page 37 SAFETY GENERAL PRECAUTIONS ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT q Before standing up from the operator's seat, lower the work equipment completely to the ground, set work equipment lock lever and parking lever securely to the LOCK position, then stop the engine. If you accidentally touch the levers when they are not Free locked, there is a hazard that the machine may suddenly...
Page 38 SAFETY GENERAL PRECAUTIONS q To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe) to ensure that you support yourself. q Do not grip the control levers, or work equipment lock lever when getting on or off the machine.
Page 39 SAFETY GENERAL PRECAUTIONS FIRE PREVENTION q Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particu- larly flammable and can be hazardous. To prevent fire, always observe the following: q Do not smoke or use any flame near fuel or oil. q Stop the engine before refueling.
Page 40 SAFETY GENERAL PRECAUTIONS q Fire coming from hydraulic line Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.
Page 41 SAFETY GENERAL PRECAUTIONS PRECAUTIONS FOR ATTACHMENTS q When installing optional parts or attachments, there may be problems with safety or legal restrictions. There- fore contact your Komatsu distributor for advice. q Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.
Page 42 SAFETY GENERAL PRECAUTIONS DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows.
Page 43 SAFETY GENERAL PRECAUTIONS CHECKING SIGNALMAN'S SIGNALS AND SIGNS q Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman. q Only one signalman should give signals.
Page 44: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION BEFORE STARTING ENGINE If there is a warning tag hanging from the work equipment con- trol lever, do not start the engine or touch the levers . CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. q Completely remove all flammable materials accumulated around the engine and battery, and remove any dirt from the windows, mirrors, handrails and steps.
Page 45 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS IN COLD AREAS q Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
Page 46: Operation
SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. q Always fasten your seat belt. q Check the operation of travel, steering and brake systems, and work equipment control system.
Page 47 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING q Never turn the starting switch to the OFF position when traveling. It is dangerous if the engine stops when the machine is traveling. When the engine is off, it is impossible to operate the steering. Apply the brakes and stop the machine immediately, if the engine stops.
Page 48 SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. q When traveling on slops, keep the blade approxmately 20 to 30 cm above the ground. In case of emergency, quickly lower the blade to the ground to help the machine to stop.
Page 49 SAFETY PRECAUTIONS FOR OPERATION PARKING MACHINE q Park the machine on level ground where there is no danger of falling rocks or landslides, or of flooding if the land is low, and lower the work equipment to the ground. q If it is necessary to park the machine on a slope, set the blocks under the tracks to prevent the machine from mov- ing, then dig the work equipment into the ground.
Page 50: Transportation
SAFETY PRECAUTIONS FOR OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. SHIPPING When shipping the machine on a trailer, do as follows. q The weight, transportation height, and overall length of the machine differ according to the work equipment, so be sure to confirm the dimensions.
Page 51: Battery
SAFETY PRECAUTIONS FOR OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. q When working with batteries, always wear safety glasses and rubber gloves. q Never smoke or use any flame near the battery.
Page 52 SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLE If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. q When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the opera- tor's seat and the other working with the battery).
Page 53: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING WHEN TOWING Injury or death could result if a disabled machine is towed incorrectly. Always observe the following rules. q Never use a towing method different from the one described in this manual. For the method of towing, see “METHOD OF TOWING MACHINE (3-141)“.
Page 54: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG q When carrying out inspection or maintenance, ALWAYS attach the “DO NOT OPERATE“ warning tag to the blade control lever in the operator's cab to alert others that you are working on the machine. Attach additional warning tags around the machine in necessary.
Page 55 SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE q Stop the machine on firm, level ground. q Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. q Lower the work equipment completely to the ground and stop the engine.
Page 56 SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.
Page 57 SAFETY PRECAUTIONS FOR MAINTENANCE HANDLING ACCUMULATOR q This machine is equipped with an accumulator. For a short time after the engine is stopped, if the work equip- ment control lever is moved to the LOWER position, the work equipment will move down under its own weight. After stopping the engine, always set the work equipment lock lever to the LOCK position.
Page 58 SAFETY PRECAUTIONS FOR MAINTENANCE NOISE When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov- ers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent hearing problems. PRECAUTIONS WHEN USING HAMMER When using a hammer, pins may fly out or metal particles may be scattered.
Page 59 SAFETY PRECAUTIONS FOR MAINTENANCE DO NOT DISASSEMBLE RECOIL SPRING Never attempt to disassemble the recoils spring assembly. It contains a spring under high pressure which serves as a shock absorber for the idler. If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work.
Page 60 SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTION FOR HIGH VOLTAGE q When the engine is running and immediately after it is stopped, high voltage is generated inside the engine con- troller and the engine injector, and there is danger of elec- trocution. Never touch the inside of the controller or the engine injector portion.
Page 61 OPERATION WARNING Please read and make sure that you understand the SAFETY section before reading this section.
Page 62: General View Of Machine
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Blade Multi ripper Blade tilt cylinder Ripper lift cylinder Blade lift cylinder Sprocket (10) Track frame Track shoe (11) Frame Ripper tilt cylinder (12) Idler...
Page 63: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Parking lever (11) Starting switch Work equipment lock lever (12) Information switch Cigarette lighter (13) Buzzer cancel switch Fuel control dial (14) Brake pedal (15) Deceleration pedal Joystick (Steering, directional and gear shift lever) (16) Blade control lever...
Page 64 OPERATION GENERAL VIEW FRONT PANEL Engine coolant temperature gauge (10) Engine pre-heating pilot lamp Power train oil temperature gauge (11) Maintenance caution lamp Hydraulic oil temperature gauge (12) Warning lampFilter/oil change interval lamp Fuel level gauge (13) Filter/oil change interval lamp Charge level caution lamp (14) Display panel A (speed range display, engine...
Page 65: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. FRONT PANEL Check monitor group Meter group...
Page 66 OPERATION EXPLANATION OF COMPONENTS B: Caution monitor group (see “CAUTION MONITOR GROUP (3-9)“) CAUTION If the caution lamp for any of these items flashes, check and repair the appropriate item as soon as possi- ble. These are items, which need to be observed while the engine is running. If any abnormality occurs, items, which need to be repaired as soon as possible, are displayed.
Page 67: Check Monitor Group
OPERATION EXPLANATION OF COMPONENTS CHECK MONITOR GROUP NOTICE q When performing the check before starting, do not rely only on these monitors. Always refer to “OPERATION (3-69)“ to perform these checks. q Park the machine on level ground and then check the monitor lamps. q Confirm that monitor lamps light up about 2 seconds after the starting switch is turned to the ON posi- tion.
Page 68 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE CAUTION LAMP This lamp (1) flashes when the time for changing the filter or oil has been exceeded. “DISPLAY PANEL B (Multi-information) (3-16)“ to the maintenance mode, and check or replace the appropriate filter or oil.
Page 69: Caution Monitor Group
OPERATION EXPLANATION OF COMPONENTS CAUTION MONITOR GROUP CAUTION If these caution lamps flash, check and repair the appropriate location as soon as possible. NOTICE q Park the machine on level ground and check the monitor lamps. q Confirm that monitor lamps light up about 2 seconds after the starting switch is turned to the ON posi- tion.
Page 70 OPERATION EXPLANATION OF COMPONENTS CHARGE LEVEL CAUTION LAMP Lamp (1) indicates an abnormality in the charging system while the engine is running. If the monitor lamp flashes, check the V-belt tension. If any abnormality is found, see “OTHER TROUBLE (3-146)“. REMARK This monitor lamp lights when the starting switch is turned to ON immediately after the engine is started or immediately...
Page 71: Emergency Caution Items
OPERATION EXPLANATION OF COMPONENTS EMERGENCY CAUTION ITEMS CAUTION If the caution lamp for any of these items flashes, stop the engine immediately or run it at low idling, and take the following action. NOTICE q Park the machine on level ground and check the monitor lamps. q Confirm that these caution lamps light for about 2 seconds after the starting switch is turned to ON.
Page 72 OPERATION EXPLANATION OF COMPONENTS ENGINE OIL PRESSURE CAUTION LAMP This lamp (1) indicates low engine oil pressure. If the monitor lamp flashes, stop the engine and check it imme- diately. REMARK The alarm buzzer sounds, when the starting switch is turned to ON immediately after the engine oil has been changed.
Page 73 OPERATION EXPLANATION OF COMPONENTS HSS CHARGE PRESSURE CAUTION LAMP This monitor (5) warns the operator that the HSS charge pres- sure has dropped. If it flashes, stop the engine and carry out inspection. REMARK The buzzer may sound when the starting switch is turned ON or immediately after the engine is started, but this does not indi- cate any abnormality.
Page 74: Meter Group
OPERATION EXPLANATION OF COMPONENTS METER GROUP NOTICE When the engine is stopped, turn that the starting switch to the ON position and check that the gauge or monitor for the engine water temperature gauge, power train oil temperature gauge, and fuel gauge light If they do not light up, please contact your Komatsu distributor for repairs.
Page 75 OPERATION EXPLANATION OF COMPONENTS POWER TRAIN OIL TEMPERATURE GAUGE Gauge (2) indicates the torque converter outlet oil temperature. If the temperature is normal during operation, green range (B) will light. If red range (C) lights up during operation, move the fuel con- trol dial to lower engine speed to approx.
Page 76 OPERATION EXPLANATION OF COMPONENTS ENGINE PRE-HEATING PILOT LAMP Lamp (5) indicates that engine is being pre-heated by the elec- trical heater during cold weather. The engine controller detects the coolant temperature and automatically actuates pre-heating in low temperatures when starting the engine. DISPLAY PANEL A (speed range display, engine speed) Meter (6) displays the transmission speed range being used on the machine and engine speed.
Page 77 OPERATION EXPLANATION OF COMPONENTS (2) Maintenance mode The maintenance mode is displayed by continuing to turn the information switch in the direction for 2.5 seconds. For details, see “METHOD OF USING DISPLAY PANEL B (Multi-information) (3-23)“. 3-17...
Page 78: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES E (1) Starting switch E (5) Rear lamp switch E (2) Buzzer cancel switch E (6) Fan rotation selector switch E (3) Information switch E (7) Auto shift down switch E (4) Front lamp switch STARTING SWITCH Switch (1) is used to start the engine.
Page 79 OPERATION EXPLANATION OF COMPONENTS BUZZER CANCEL SWITCH When this switch (2) is turned to the right, the alarm buzzer stops. When the information monitor is in the maintenance mode, this switch is used to select the mode item. Position (a): Cancel Position (b): Select INFORMATION SWITCH This switch (3) is used to switch the display mode item on the...
Page 80 OPERATION EXPLANATION OF COMPONENTS FAN ROTATION SELECTOR SWITCH This switch (6) is used to switch the fan to the reverse mode and clean mode. Position (a): Normal mode Position (b): Reverse mode Position (c): Clean mode q Use the reverse mode in cold weather to maintain the tem- perature and use the clean mode when removing dirt and foreign material clogging the radiator.
Page 81: Lamps
OPERATION EXPLANATION OF COMPONENTS LAMPS F (1) Warning lamp F (3) Fan operation confirmation lamp F (2) Filter/oil change interval lamp WARNING LAMP NOTICE If alarm buzzer sounds, stop work immediately and per- form inspection and maintenance of the appropriate point. When the caution lamp for the B CAUTION or C CAUTION groups flashes and an abnormality is detected by the electronic control system, the alarm buzzer sounds and this lamp (1)
Page 82 OPERATION EXPLANATION OF COMPONENTS FILTER/OIL CHANGE INTERVAL LAMP This lamp (2) lights up when the time for replacing the filter or oil is near. FAN OPERATION CONFIRMATION LAMP After the engine is started, even if the fan rotation selector switch is operated, this lamp will flash to inform the operator that the switching operation cannot be carried out.
Page 83: Method Of Using Display Panel B (Multi-Information)
OPERATION EXPLANATION OF COMPONENTS METHOD OF USING DISPLAY PANEL B (Multi-information) EXPLANATION OF MODES AND CONTROLS q Display panel B (1) has the function of displaying the fol- lowing four types of mode. (The diagram on the right shows the normal screen before the mode display.) Maintenance mode This displays the time for replacing the filters or oil.
Page 84 OPERATION EXPLANATION OF COMPONENTS METHOD OF SELECTING MODES 1. When moving from the normal operation display to a user mode, the maintenance mode is displayed. Use the con- trols to change the mode as follows. > position: Go to PM clinic auxiliary mode <...
Page 85 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING MAINTENANCE MODE NOTICE This function is only a guideline. If dirty oil or filters are found during daily maintenance, replace them immediately. If the controllers or monitor panel are replaced, the timer for this function will not work properly. Contact your Komatsu distributor for replacement.
Page 86 OPERATION EXPLANATION OF COMPONENTS REMARK To return to the function selection mode, operate the buzzer cancel switch to 3-26...
Page 87 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING PM CLINIC AUXILIARY MODE CAUTION When moving the work equipment or setting the transmission to the travel position for carrying out mea- surements, check carefully that the situation is safe. The PM clinic auxiliary mode displays the engine speed, hydraulic oil pressure, and other items on display panel Display panel B displays the item on the top line (1), and the measured value on the bottom line (2).
Page 88 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 89 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING USER ADJUST MODE With the user adjust mode, the brightness of the panel screen backlighting and the contrast of the liquid crystal panel can be changed, or the cooling fan can be set to maximum speed to clean the radiator when it is clogged. These are displayed on display panel B.
Page 90 OPERATION EXPLANATION OF COMPONENTS The brightness can be adjusted by operating the information 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 When the buzzer cancel switch is operated to , the bright- ness of the message display backlighting is set.
Page 91 OPERATION EXPLANATION OF COMPONENTS REMARK To return to the function selection mode, operate the buzzer cancel switch to The brightness of the backlighting of the monitor panel differs according to whether the front lamp is lit or not. Entering this mode when the front lamps are lit makes it possible to adjust the brightness when the front lamps are lit.
Page 92: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Horn switch Cigarette lighter (24V) Room lamp switch Accessory socket (12V) Wiper switch HORN SWITCH The horn sounds when button (1) at rear of the blade control lever on the right side of operator's seat is pressed. ROOM LAMP SWITCH This (2) lights up the room lamp.
Page 93 OPERATION EXPLANATION OF COMPONENTS WIPER SWITCH Switch (3) activates the wipers. The wiper switches are as follows: (LH) Left door (FF) Front window (RH) Right door (RR) Rear window (INT) Wiper intermittent operation switch This is also used as the window washer switch. The switch is operated as follows: q Window washer only Keep the switch pressed to the OFF position to spray out...
Page 94 OPERATION EXPLANATION OF COMPONENTS q If the intermittent switch is turned ON, all movement of the wipers will be intermittent. 3-34...
Page 95 OPERATION EXPLANATION OF COMPONENTS REMARK When installing the cab, check the colors and install the washer tank and each window washer hose correctly according to the color. When installing the cab, carry out the operation in accordance with the cab installation procedure manual held by your Komatsu distributor.
Page 96 OPERATION EXPLANATION OF COMPONENTS CIGARETTE LIGHTER Lighter (4) 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 97: Control Levers, Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS Fuel control dial Work equipment lock lever Blade control lever Joystick (steering, directional and gear shift lever) Ripper control lever (Variable ripper) Brake pedal Pin puller control switch (giant ripper)(if equipped) Deceleration pedal Parking lever FUEL CONTROL DIAL Dial (1) is used to control the engine speed and output.
Page 98 OPERATION EXPLANATION OF COMPONENTS JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) (PCCS lever) This lever (2) is used to switch between forward and reverse, to steer the machine, or carry out counterrotation turns. REMARK PCCS: Palm command control system Forward-reverse shifting Position (a): FORWARD Position (b): REVERSE Position N: Neutral...
Page 99 OPERATION EXPLANATION OF COMPONENTS Operating counter-rotation turn WARNING When operating the counter-rotation turn, if the load on the left and right is not balanced, the machine may make a pivot turn, so check the ground conditions and be careful not to hit any obstacles when carrying out the operation. With the lever in the N position, move the lever partially in the direction of turn.
Page 100 OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING Do not place your foot on this pedal unnecessarily. Depress the pedal (3) to apply the right and left brakes. DECELERATION PEDAL WARNING 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...
Page 101 OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT LOCK LEVER WARNING q When standing up from the operator's seat, always move the work equipment lock lever securely to the LOCK position. Free If the blade control and ripper control levers are not locked and are touched by accident, it may lead to serious injury or damage.
Page 102 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER Single tiltdozer Lever (7) is used to raise or tilt the blade. q Lifting control (a) RAISE: Raise (b) HOLD: Blade is stopped and held in this position. (c) LOWER: (d) FLOAT: Lower Blade will move freely according to external force.
Page 103 OPERATION EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER This lever (8) is used to operate the ripper. (a) RAISE (b) HOLD: Ripper stops and stays in same position (c) LOWER Raise Lower (A) Digging angle reduced: Cutting angle (α) becomes smaller. (B) Digging angle increased: Cutting angle (α) becomes larger.
Page 104: Dust Indicator
OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR This informs the operator if the air cleaner element becomes clogged. For details of the method for cleaning the element, see “WHEN REQUIRED (4-21). POWER SOURCE It is possible to remove the cigarette lighter and use the socket as a power supply. Capacity of cigarette lighter: 120W (24V x 5A) NOTICE Do not use this as the power supply for 12V equipment.
Page 105: Fuse Box
OPERATION EXPLANATION OF COMPONENTS FUSE BOX NOTICE Before replacing a fuse, be sure to turn starting switch to the OFF position. Fuses protect the electrical equipment and wiring from burning out. If a fuse becomes corroded, or white powder can be seen, or a fuse is loose in the holder, replace the fuse. Replace a fuse with another of the same capacity.
Page 106 OPERATION EXPLANATION OF COMPONENTS q Cab (machines equipped with cab) Fuse box is installed at the bottom of the overhead panel. 3-46...
Page 107: Circuit Breaker
OPERATION EXPLANATION OF COMPONENTS CIRCUIT BREAKER q If the starting switch does not work even when the starting switch is turned to the ON position, open the recirculated air filter cover to gain access to the circuit breaker. q If excessive current flows through the circuit breaker, it cuts off the electric circuit to prevent damage to the electrical components and wiring.
Page 108: Fuse Capacity And Name Of Circuit
OPERATION EXPLANATION OF COMPONENTS REMARK The capacity of circuit breakers (A) and (B) is as follows. (A): 30A (for regular cab power supply) (B): 105A (for general power supply) FUSE CAPACITY AND NAME OF CIRCUIT FUSE BOX I (1) Fuse box fs1 Fuse Circuit capacity...
Page 109: Door Pocket
OPERATION EXPLANATION OF COMPONENTS DOOR POCKET This is inside the left and right doors. Use them for storing things. Do not put heavy tools or other heavy objects in them. If the pocket is dirty, loosen four bolts (1), then remove the pocket and rinse it.
Page 110: Car Radio, Handling
OPERATION EXPLANATION OF COMPONENTS CAR RADIO, HANDLING EXPLANATION OF COMPONENTS Power switch, volume knob Seek button (SEEK) Tone control knob Tuning button Display Preset station buttons Display selector button (CLOCK) FM/AM selector button (BAND) Station selector button (AST) POWER SWITCH, VOLUME KNOB When this knob (1) is turned clockwise from the OFF position, a click is heard and the power is turned on.
Page 111 OPERATION EXPLANATION OF COMPONENTS STATION SELECTOR BUTTON (AST) When this button (5) is pressed, the preset stations are called up in turn. When the desired broadcasting station is reached, press the button again to stop it. If this button is kept pressed for 2 seconds, it switches to auto memory. SEEK BUTTON (SEEK) When this button (6) is pressed, it automatically searches for stations that can be received.
Page 112: Method Of Use
OPERATION EXPLANATION OF COMPONENTS METHOD OF USE METHOD OF LISTENING TO RADIO 1. Turn the starting switch ON, then turn radio power switch (1) ON. 2. Use BAND button (9) to select AM or FM. 3. Select the channel with PRESET STATION button (8) or TUNE button (7).
Page 113 OPERATION EXPLANATION OF COMPONENTS METHOD OF PRESETTING 1. Select the desired preset station. Use BAND button (9) to select FM or AM, then use TUNE button (7) to select the frequency of the broadcasting sta- tion. 2. Decide one of preset buttons (8) to be used for the preset station, and keep it pressed for 2 seconds.
Page 114: Precautions When Using
OPERATION EXPLANATION OF COMPONENTS MONAURAL/STEREO AUTOMATIC SELECTION RECEPTION If the reception of the FM stereo broadcast is weak (when you are far from the broadcasting station or are sur- rounded by hills), the radio is automatically switched from stereo to monaural to reduce the interference. When the stereo broadcast becomes stronger, it automatically switches back to stereo broadcasting.
Page 115: Car Stereo, Handling
OPERATION EXPLANATION OF COMPONENTS CAR STEREO, HANDLING EXPLANATION OF COMPONENTS Power switch/volume Cassette door Auto-store/preset scan button Fast forward, rewind buttons Bass control knob (10) Preset buttons Treble control knob (11) Metal tape button Loudness button (12) Manual tuning buttons Time/radio display selector button (13) Seek tuning buttons...
Page 116 OPERATION EXPLANATION OF COMPONENTS POWER SWITCH/VOLUME Turn this knob (1) to the right until it clicks to turn the power on. Turn it further to increase the volume. AUTO-STORE/PRESET SCAN BUTTON Use this button (2) to actuate the preset scan and auto-store functions. q Auto-store Each time this button is pressed for more than 2 seconds while in radio reception, this auto-store function automatically starts to search for the desired station within a receivable band, and memorize the frequency in...
Page 117 OPERATION EXPLANATION OF COMPONENTS CASSETTE DOOR Set the cassette with the exposed portion of the tape on the right side and insert it through the cassette door (8). FAST FORWARD, REWIND BUTTONS These buttons (9) are used to fast-forward or rewind the tape. q Fast forward/rewind If you press the button pointing in the same direction as the arrow indicating the direction of play, the tape will be fast forwarded;...
Page 118: Method Of Operation
OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS To listen to a preset station, use band selector button (1) to select AM, FM1, or FM2, then press the preset switch number to listen to the desired station. It is possible to preset six AM stations and 12 FM stations (FM1: 6, FM2: 6).
Page 119 OPERATION EXPLANATION OF COMPONENTS LISTENING TO RADIO 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Set band selector button (2) to AM or FM. 3. Select the station with the preset buttons or manual tuning button (3).
Page 120: Precaution When Using
OPERATION EXPLANATION OF COMPONENTS REVERSING TAPE When listening to the tape, press both FAST FORWARD, REWIND buttons (A) and (B) at the same time lightly. When this is done, the tape direction display will be reversed. PRECAUTION WHEN USING WARNING q If a voltage greater than the specified voltage is input, it may cause fire, electrocution, or other failure.
Page 121: Air Conditioner
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL FOOT Temperature display lamp Fan switch Fresh/recirc selector switch Air conditioner switch Temperature control switch FAN SWITCH This switch (1) can be used to adjust the airflow in four stages. It also acts as the main switch for the air conditioner.
Page 122 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 123: 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 124: Precautions When Using
OPERATION EXPLANATION OF COMPONENTS WHEN NOT USING THE AIR CONDITIONER REGULARLY Run the air conditioner in cooling or dehumidification + heating mode for several minutes from time to time to pre- vent the loss of the oil film in various parts of the compressor. REMARK If the temperature inside the cab is low, the air conditioner may not work.
Page 125: Procedure For Replacing Receiver
OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR REPLACING RECEIVER Replace the receiver once every two years. After replacing the receiver, add compressor oil. Turn the receiver at an angle and measure the oil remaining inside the receiver, then add the same amount of oil (Denso Oil 6) to fill the receiver. REMARK The replacement interval may become shorter depending on the conditions during use.
Page 126: Skillful Use Of Air-Conditioner
OPERATION EXPLANATION OF COMPONENTS SKILLFUL USE OF AIR-CONDITIONER WHEN WANTING TO COOL INSIDE OF CAMP QUICKLY If the machine is left in the sun in the middle of summer, the temperature inside the cab may become extremely high. If this happens and it is desired to cool the cab quickly, first open all the doors and windows to remove all the hot air, then turn the air conditioner on.
Page 127: Heater, Handling
OPERATION EXPLANATION OF COMPONENTS HEATER, HANDLING METHOD OF OPERATION Switchs RECIRC/ Condition of use Humidity control Fan switch FRESH selector switch switch Rapid heating All red RECIRC Ventilation or pressurization HI - LO All blue FRESH TO HEAT QUICKLY If the switch is operated as follows, the cab can be heated quickly.
Page 128: Accumulator, Handling
OPERATION EXPLANATION OF COMPONENTS ACCUMULATOR, HANDLING WARNING On machines equipped with an accumulator, for a short time after the engine is stopped, if the work equip- ment control lever is moved to the LOWER position, the work equipment will move down under its own weight.
Page 129: 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 130 OPERATION OPERATION 6. Check for damage to handrail, loose bolts. Repair any damage and tighten any loose bolts. 7. Check for damage to gauges, lamps on the instrument panel and loose bolts. Check for damage to the panel, gauges and lamps. If any abnormality is found, replace the parts. Clean off any dirt on the surface.
Page 131: Check Before Starting
OPERATION OPERATION CHECK BEFORE STARTING Always check the items in this section before starting the engine each day. CHECK MONITOR PANEL 1. Turn starting switch (1) to the ON position. 2. Check that all monitors and gauges light up for approx. 2 seconds and that the alarm buzzer sounds for approx.
Page 132 OPERATION OPERATION CHECK COOLANT LEVEL, ADD COOLANT WARNING q Normally, do not open the radiator cap. When checking the coolant level, check the sub-tank when the engine is cold. q Do not remove the cap when the radiator coolant is hot. Boiling coolant may spurt out. After the cool- ant temperature goes down, turn the cap slowly to release the pressure, then remove it.
Page 133 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When refilling fuel in the fuel tank, do not spill or let it overflow. The spilt fuel may catch fire. If spilt, wipe it off cleanly. Never expose fuels to fire as they are inflammable and thus dangerous material. 1.
Page 134 OPERATION OPERATION CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT (Machines equipped with additional fuel filter cartridge) 1. Open the side cover on the left side of the machine. The water separator forms one unit with the additional fuel filter and is installed at the bottom. 2.
Page 135 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 136 OPERATION OPERATION CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL 1. Remove dipstick (G), and wipe the oil off with a cloth. 2. Fully insert dipstick (G) into filler pipe (F), then remove it. 3. Check that the oil level is between the H and L marks on dipstick (G).
Page 137 OPERATION OPERATION CHECK BRAKE PEDAL TRAVEL Drive the machine, depress the brake pedal, and check that the machine stops. CHECK DAMPER CASE OIL LEVEL, ADD OIL 1. Open the engine side cover on the left side of the machine. 2. Remove dipstick (G), and wipe the oil off with a cloth. 3.
Page 138 OPERATION OPERATION CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING q When removing the oil filler cap, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap.
Page 139 OPERATION OPERATION CHECK DUST INDICATOR 1. Check for the yellow piston overlapping the red zone on the dust indicator (1). 2. If the yellow piston is overlapping the red zone, clean or replace the element immediately. For details of the method of cleaning the element, see “CHECK, CLEAN AND REPLACE AIR CLEANER ELE- MENT (4-24)“.
Page 140 OPERATION OPERATION CHECK THAT LAMPS LIGHT UP 1. Turn starting switch key to the ON position. 2. Turn the front lamp switch to the ON (b) position and check that the front lamp light up. 3. Turn the rear lamp switch to the ON (b) position and check that the rear lamps on the left and right fenders light up.
Page 141 OPERATION OPERATION CHECK HORN SOUND 1. Turn starting switch key to the ON position. 2. Push the horn switch and check that the horn sounds. CHECK BACKUP ALARM SOUND 1. After starting the engine, run it at idle, completely depress the brake, and release the parking lever.
Page 142: Adjustment
OPERATION OPERATION ADJUSTMENT WARNING q Carry out adjustment before starting operations and when the operators change shifts. q Adjust the seat so that you can depress the brake pedal fully with your back pressed against the back- rest of the operator's seat. ADJUSTING OPERATOR'S SEAT (A) Fore-and-aft adjustment Pull lever (1), set the seat to a position where it is easy to oper-...
Page 143 OPERATION OPERATION USING SEAT BELT WARNING q Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions. Replace any worn or damaged seat belt or the securing brackets. q Even if no abnormality can be seen in the belt, replace the seat belt every 3 years. The date of manu- facture of the belt is shown on the back of the belt.
Page 144 OPERATION OPERATION ADJUST MIRROR Loosen nut (1) of the mirror and adjust the mirror to a position where it gives the best view from the operator's seat. In particular, be sure to adjust the mirror so that people at the rear left or right of the machine can be seen clearly.
Page 145 OPERATION OPERATION ADJUST ARMREST The height of the armrest on the left and right sides of the operator's seat can be adjusted to 3 positions. After adjusting the operator's seat, adjust the armrest to a suitable height. ADJUST ARMREST (RIGHT) Armrest (1) on the right side of the operator's seat can be adjusted in 3 stages: up 30 mm, standard height (cen- ter), or down 25 mm.
Page 146: Operations And Checks Before Starting Engine
OPERATION OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING q When starting the engine, check and make sure the work equipment lock lever (4) and parking lever (1) are secured in the LOCK position. If the control levers are not locked and they are touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious injury or death.
Page 147 OPERATION OPERATION 3. Check that the blade is lowered to the ground and that blade control lever (3) is in the HOLD position. If it is in the Float Lower FLOAT position, the engine will not start. Hold Raise Hold Raise Lower 4.
Page 148: 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 seri- ous 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 149 OPERATION OPERATION 2. Turn the key of starting switch (2) to the START position. 3. When engine is started, release the key of starting switch (2) and the key will return automatically to ON. 3-89...
Page 150: Starting In Cold Weather
OPERATION OPERATION STARTING IN COLD WEATHER WARNING q Start the engine only after sitting down in the opera- tor'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.
Page 151 OPERATION OPERATION 3. Check that engine pre-heating pilot lamp (3) on the monitor panel lights up. 4. Maintain the key in the on position until the pre-heating pilot lamp (3) goes off. 5. When pre-heating pilot lamp (3) goes off, turn the key of starting switch (2) to the START position to crank the engine.
Page 152 OPERATION OPERATION REMARK Regardless of the ambient temperature, if the key in the starting switch (2) is turned from the OFF position to the left, pre-heating pilot lamp (3) will light up and pre-heating will start. (Pre-heating continues while the starting switch is being held to the left.) For details of the pre-heating time, see the table in Step 5.
Page 153: 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 sufficiently warming up the machine, the response of the work equipment to the movement of the control levers will be slow and may not move as the operator desires.
Page 154: In Cold Areas
OPERATION OPERATION 3. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu dis- tributor. IN COLD AREAS 1. Turn fuel control dial (1) to the center position between low idling (MIN) and high idling (MAX) positions and run the engine at a mid-range speed for 10 minutes under no load.
Page 155: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be drastically shortened. Do not abruptly stop the engine except for an emergency. If the engine has overheated, do not stop it abruptly, run it at medium speed allowing the engine to gradually cool down, then stop it.
Page 156: Moving Machine
OPERATION OPERATION MOVING MACHINE WARNING q Before moving the machine, check that the area around the machine is safe, and always sound the horn before moving. Do not allow anyone to enter the area around the machine. The rear of the machine is a bl ind spot, so be extremely careful when traveling in reverse.
Page 157 OPERATION OPERATION 3. Operate blade control lever (3) and ripper control lever (4) to the RAISE position, raise the blade 40 - 50 cm from the Float Lower ground, and raise the ripper to the maximum height. Hold Raise Hold Raise Lower 4.
Page 158: Stopping Machine
OPERATION OPERATION STOPPING MACHINE WARNING q Avoid stopping suddenly. Give yourself ample room when stopping. q When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably neces- sary to park the machine on a slope, place the parking lever (1) in the LOCK position and insert blocks under- neath the track shoes.
Page 159: Shifting Gear
OPERATION OPERATION SHIFTING GEAR The machine does not have to be stopped to shift gears. 1. Move steering, forward-reverse, gear shift lever (1) to the desired gear position to shift gears. GEAR SHIFTING q The transmission speed will change when switch (a) or switch (b) is pushed.
Page 160 OPERATION OPERATION GEARSHIFTING OPERATION USING PRESET MODE FUNCTION q Shift mode selection means that the selected speed range is displayed in the N position before starting. q When the joystick is in the N position, if UP switch (a) or DOWN switch (b) is pressed, the shift mode selection can be carried out.
Page 161 OPERATION OPERATION AUTO SHIFT DOWN FUNCTION When the load conditions during travel cause the travel speed to drop, this function automatically shifts the transmission down to a lower speed range. This function can be used by setting the auto shift down switch (3) on the instrument panel in front of the operator's seat to the ON (b) position.
Page 162: Shifting Between Forward And Reverse
OPERATION OPERATION SHIFTING BETWEEN FORWARD AND REVERSE WARNING When switching between FORWARD and REVERSE, first check that the direction of travel is safe. CAUTION There is no need to stop the machine even when switching between FORWARD and REVERSE. To increase safety, operator comfort, and the life of the transmission, leave the engine running at full speed, and always depress the decelerator pedal to lower the engine speed.
Page 163 OPERATION OPERATION 4. Release decelerator pedal (1) and raise the engine speed. REMARK When the joystick is placed in REVERSE, the backup alarm will sound. 3-103...
Page 164: 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 To turn the machine while traveling, incline steering, forward- reverse, gear shift lever (1) in the direction of the turn.
Page 165: Turning While Descending A Slope
OPERATION OPERATION COUNTERROTATION TURNS TO LEFT WHEN TRAVELING FORWARD NOTICE When carrying out a counterrotation turn, if the load is not equal on the left and right sides, the machine may carry out a pivot turn, so check the ground conditions and be careful not to hit any obstacles.
Page 166: Precautions For Operation
OPERATION OPERATION PRECAUTIONS FOR OPERATION PAY ATTENTION TO GAUGES If the red range of the power train oil temperature gauge lights up during operation, reduce the load and wait for the temperature to go down. PERMISSIBLE WATER DEPTH When operating in water, always keep top surface of the track frame above the surface of the water.
Page 167: Precautions On Slope
OPERATION OPERATION PRECAUTIONS ON SLOPE BE CAREFUL OF FUEL LEVEL q If the fuel level in the fuel tank becomes low when the machine is working on slopes, the engine may suck in air because of the angle of the machine or the swaying of the machine. This may make the engine stop, so be careful not to let the fuel level in the fuel tank become too low.
Page 168: Precautions For Blind Spots Caused By Cab Stay And Rops Stay
OPERATION OPERATION PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY WARNING The cab stay and ROPS stay cause blind spots. When operating, always be sure to check carefully that there is no obstacle or worker in the surrounding area. PARKING MACHINE WARNING q Avoid stopping suddenly.
Page 169: Check After Stopping Engine
OPERATION OPERATION 2. Set joystick (steering, directional, and gearshift lever) (3) to the N position. 3. Operate parking lever (4) to lock the brakes. Free Lock 4. Operate blade control lever (5) and ripper control lever (6) to the LOWER position, and lower the blade and ripper to Float Lower the ground.
Page 170: Check After Finishing Work
OPERATION OPERATION CHECK AFTER FINISHING WORK Use the meters and caution lamps to check the engine coolant temperature, engine oil pressure, fuel level, and Power train oil temperature. LOCKING To prevent vandalism, there are locks in the following places. Places that can be locked with the starting switch key. q Left and right engine side covers (1) Left and right engine side covers (1) (left side: 2 places;...
Page 171: Ripper Operation
OPERATION OPERATION RIPPER OPERATION EFFECTIVE METHOD OF USE q The most suitable digging angle for the shank is when the shank is perpendicular to the ground surface (angle at tip: 45° - 50°). q For comparatively soft rock (seismic velocity: 1200m/s or below), it is also possible to carry out ripping with the shank tilted to the rear (maximum ripping angle).
Page 172: Operating On Slopes
OPERATION OPERATION OPERATING ON SLOPES When using the variable ripper, adjust the length of the tilt cylin- der to select dimension L. Slope face: Sloping face, such as on embankments METHOD OF OPERATING PIN PULLER This operation is used only when a giant ripper is installed. Top surface 1.
Page 173: Operating Method For Ripping Operations
OPERATION OPERATION OPERATING METHOD FOR RIPPING OPERATIONS BASIC OPERATING METHOD Shank tilted back Start lowering ripper Point in contact with ground Ripping Insert point to Start raising specified depth ripper TRACK OF RIPPER SHANK Carry out the ripping operation as follows, passing through the points shown in the diagram above. (1) Tilt the ripper back, lower the ripper point to the ground that the place to begin ripping, and raise the rear of the machine.
Page 174: Ripping By Cliffs
OPERATION OPERATION RIPPING BY CLIFFS q When carrying out ripping at the edge of a cliff, tilt the rip- per back to make depth (L) longer. Tilt back (MAX) q Depress the decelerator pedal, drive slowly forward, and when the ripper point contacts the cliff, tilt the ripper. Cliff RIPPING BY SLOPE FACES (Giant ripper)
Page 175: Digging Up Boulders
OPERATION OPERATION DIGGING UP BOULDERS During the ripping operation, if boulders are found which are difficult to break and shoe slippage occurs, dig up the boulder as follows. 1. Depress the decelerator pedal and lower the engine speed to a point where there is no shoe slippage. 2.
Page 176: Precautions When Ripping
OPERATION OPERATION PRECAUTIONS WHEN RIPPING q For the digging angle when ripping, set so that the top of the shank is perpendicular, then lower the ripper. q Do not carry out ripping for long periods with the shank tilted back. The tip of the point will wear to a round shape. q Do not change the direction of travel during the ripping operation.
Page 177 OPERATION OPERATION q If ripping operations are carried out with the shank at the maximum length on bedrock, the point will not penetrate the ground properly. This will cause an increase in the load and may lead to breakage of the shank. For this reason, avoid carrying out operations on bedrock with the shank at the maximum length.
Page 178: Work Possible Using Bulldozer
OPERATION OPERATION WORK POSSIBLE USING BULLDOZER If various attachments are used, it is possible to carry out operations in a wider range than listed below. DOZING A bulldozer digs and transports dirt in a forward direction. Slope excavation can always be most effectively carried out by proceeding from the top downward.
Page 179: Cutting Into Hard Or Frozen Ground Or Ditching
OPERATION OPERATION CUTTING INTO HARD OR FROZEN GROUND OR DITCHING For digging and ditch excavation of hard or frozen ground, tilt the blade. Even hard ground can be dug effectively by a tilted or angled blade. FELLING TREES, REMOVING STUMPS NOTICE Do not uproot trees or stumps or fell trees by angling or tilting the blade.
Page 180: Adjusting Posture Of Work Equipment
OPERATION OPERATION ADJUSTING POSTURE OF WORK EQUIPMENT 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 181 OPERATION OPERATION REMARK When assembling a C-frame to an angledozer, adjust the length of arm (2) and brace (3) so that clearance S of center joint (4) is 20 mm. Clearance S Center joint Section A - A 3-121...
Page 182: Adjusting Tilt Amount
OPERATION OPERATION ADJUSTING TILT AMOUNT (Angledozer, power tiltdozer) 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 183 OPERATION OPERATION 3. Tighten set bolt (1). NOTICE The standard distance between the brace joints is 1493 mm, but do not exceed a maximum tilt of 400 mm when carrying out operations. If the tilt exceeds 400 mm, exces- sive force will be generated at various parts. POWER TILTDOZER NOTICE The maximum tilt is 1000 mm.
Page 184: Adjusting Ripper
OPERATION OPERATION ADJUSTING RIPPER ADJUSTING DIGGING DEPTH There are mounting holes in the shank to chose to match the ripping depth. Normally, use the bottom hole, but if particularly deep ripping is needed, use the top hole. When changing the ripping depth, do as follows. 1.
Page 185: Adjust Angle Of Blade Edge
OPERATION OPERATION ADJUST ANGLE OF BLADE EDGE (Angledozer, power tiltdozer) 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 186: Tips For Longer Undercarriage Life
OPERATION OPERATION TIPS FOR LONGER UNDERCARRIAGE LIFE Undercarriage life greatly varies depending on operation method, inspection and maintenance. For most efficient operation, keep the following points in mind. OPERATION METHOD q Select the track shoe that best suits the type of soil to be encountered in service. Consult your Komatsu distributor when selecting track shoes.
Page 187: Inspection And Adjusting
OPERATION OPERATION INSPECTION AND ADJUSTING q Adjust the track shoe to the proper tension. When adjusting the tension, measure clearance A between Clearance A the idler and carrier roller in the diagram on the right. The normal clearance is 20 to 30 mm, but on bedrock, set the tension slightly higher, and on viscous ground, set it slightly looser.
Page 188: Inspection And Repair
OPERATION OPERATION INSPECTION AND REPAIR Frequent inspection and prompt repair will reduce repair costs. The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per- form periodical inspection and contact the Komatsu distributor in your area when machine has approached repair- able limits and reversing limits.
Page 189 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 190: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. LOADING, UNLOADING WORK WARNING q Use ramps with ample width, length, and thickness to allow safe loading and unloading. If the ramps bend excessively, reinforce them with blocks. q Select firm, level ground when loading the machine.
Page 191: Method Of Lifting Machine
OPERATION TRANSPORTATION 6. When transporting the machine, place wooden blocks under the front and rear track shoes to prevent the machine from moving. Also, hold it down with chains or wire rope of a suitable strength. Be particularly care- ful to ensure that the machine does not slip sideways. METHOD OF LIFTING MACHINE WARNING q Never perform lifting operations with any person on the machine.
Page 192: Precautions For Transportation
OPERATION TRANSPORTATION PRECAUTIONS FOR TRANSPORTATION WARNING Determine the route for transporting the machine by taking into account the width, height and weight of the machine. Obey all state and local laws governing the weight, width and length of a load. Observe all regulations governing wide loads.
Page 193: Removal Of Cab
OPERATION TRANSPORTATION REMOVAL OF CAB (Machines equipped with cab) If it is necessary to remove the cab for transporting, disconnect the washer hoses, cab power source, and washer motor wiring from the socket before removing the cab. 1. Pull the grommet portion in towards the cab from the hole in the machine cover, then remove.
Page 194 OPERATION TRANSPORTATION REMARK When installing the cab, check the colors and install the washer tank and each window washer hose correctly. When installing the cab, carry out the operation in accordance with the cab installation procedure manual held by your Komatsu distributor.
Page 195: 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 196: Battery
OPERATION COLD WEATHER OPERATION BATTERY WARNING q The battery generates flammable gas. Do not bring fire or sparks near the battery. q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 197: After Cold Weather
OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER When the season changes and the weather becomes warmer, do as follows. q Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (4-12)“. 3-137...
Page 198: 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 199: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. Always watch the fuel level and be careful not to run out of fuel. If the engine has stopped because of lack of fuel, it is necessary to use the priming pump to bleed the air com- pletely from the fuel circuit.
Page 200 OPERATION TROUBLESHOOTING 8. Push in several times until lever (5) becomes stiff. 9. Install bolt (6) and nut (7) of priming pump (3), then lock lever (5). 10. Turn the key in the starting switch to the START position and start the engine. When doing this, do not crank the starting motor continuously for more than 20 seconds.
Page 201: Method Of Towing Machine
OPERATION TROUBLESHOOTING METHOD OF TOWING MACHINE WARNING q Be sure to use a wire rope sufficiently strong for the towing weight. q When using the towing hook, be sure to use a shackle. q Set the wire rope level and align it with the track frame. q Tow the machine slowly.
Page 202: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING When removing q It is dangerous to charge a battery when mounted on a disconnect the machine. Make sure that it is dismounted before cable from the charging. ground terminal first. q When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position.
Page 203: Precautions When Charging Battery
OPERATION TROUBLESHOOTING PRECAUTIONS WHEN CHARGING BATTERY When charging the battery, if the battery is not handled cor- rectly, there is danger that the battery may explode. Always follow the instructions in “IF BATTERY IS DISCHARGED (3- 142)“ and the instruction manual accompanying the charger, and do as follows.
Page 204 OPERATION TROUBLESHOOTING 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. q Be careful not to let the normal machine and problem machine contact each other.
Page 205 OPERATION TROUBLESHOOTING STARTING THE ENGINE 1. Make sure the clips are firmly connected to the battery terminals. 2. Start the engine of the booster machine and keep it running at high idling speed. 3. Turn the starting switch of problem machine to the START position, and start the engine. If the engine doesn't start at first, try it again after 2 minutes.
Page 206: Other Trouble
OPERATION TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even •Defective wiring...
Page 207: Monitor Panel
OPERATION TROUBLESHOOTING MONITOR PANEL When an error code appears on the service meter display, take appropriate remedies based upon the table below. Error code Remedy Problem •Abnormality in back-up alarm relay Automatic functions stop and some of the other •Abnormality in engine speed display sensor functions stop, but operation is possible.
Page 208: Chassis
OPERATION TROUBLESHOOTING CHASSIS q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy When brake pedal is depressed, •Brakes out of adjust, defective (•Check, adjust, repair) machine does not stop...
Page 209: Engine
OPERATION TROUBLESHOOTING ENGINE q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pressure caution lamp •Add oil to specified level, see •Engine oil pan oil level is low (suck- flashes when engine speed is raised...
Page 210 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) 3-150...
Page 211: Maintenance
MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 212: Guides To Maintenance
MAINTENANCE GUIDES TO MAINTENANCE GUIDES TO MAINTENANCE Do not perform any inspection and maintenance operation that is not found in this manual. Stop the machine on flat hard ground when performing inspections and maintenance. 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 213 MAINTENANCE GUIDES TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: q Inspect the air cleaner clogging monitor frequently to see if the air cleaner is clogged. Clean the air cleaner element at a shorter interval than specified. q Clean the radiator core frequently to avoid clogging.
Page 214 MAINTENANCE GUIDES TO MAINTENANCE PRECAUTIONS WHEN OPENING AND CLOSING ENGINE SIDE COVER: q When standing on track to open the engine side cover, adopt a standing position, hold the side cover with both thumbs, and open it slowly with your other fingers. q When the side cover is open, do not open or close the cab.
Page 215: Outlines Of Service
MAINTENANCE OUTLINES OF SERVICE OUTLINES 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 216: Fuel
MAINTENANCE OUTLINES 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 217: Carrying Out Kowa (Komatsu Oil Wear Analysis)
MAINTENANCE OUTLINES OF SERVICE CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other problems.
Page 218: Storing Oil And Fuel
MAINTENANCE OUTLINES OF SERVICE STORING OIL AND FUEL q Keep indoors to prevent any water, dirt, or other impurities from getting in. q When keeping drum cans for a long period, put the drum on its side so that the filler port of the drums is at the side to prevent moisture from being sucked in.
Page 219: Handling Hydraulic Related Equipment
MAINTENANCE OUTLINES OF SERVICE HANDLING HYDRAULIC RELATED EQUIPMENT q During operations and after completion of operations, the hydraulic equipment is at a high temperature. Dur- ing operations, it is also under high pressure, so when carrying out inspection and maintenance of hydraulic related equipment, be careful of the following points.
Page 220: Wear Parts List
MAINTENANCE WEAR PARTS LIST WEAR PARTS LIST Wear parts such as the filter element, air cleaner element etc. are to be replaced at the time of periodic mainte- nance or before their abrasion limits. The wear parts should be changed correctly in order to use the machine economically. When changing parts,use Komatsu genuine parts of excellent quality.
Page 221 MAINTENANCE WEAR PARTS LIST WEAR PARTS LIST The parts in parentheses are to be replaced at the same time. Weight Replacement Item Part No. Part Name Q'ty (kg) frequency Engine oil filter 600-211-1340 Cartridge 07063-01100 Element Power train filter (07000-02130) (O-ring) Every 500 Fuel filter...
Page 222: 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 223: 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 TEMPERATURE Reservoir Fluid type Recommended komatsu Fluids SAE0W30EOS and HTHS 3.5min. -30°C 30°C (Note.1) Komatsu EOS0W30 SAE5W40EOS and HTHS 3.5min. -25°C 40°C (Note.1) Komatsu EOS5W40 Engine oil pan Engine oil...
Page 224: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT 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. For this reason, it requires high precision for the parts and good lubrication.
Page 225: 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 226: 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 227 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q'ty Replacement interval 19 PPC lock valve PPC valve (blade) 20 PPC lock valve PPC valve (ripper) 21 HSS, PPC charge valve CLSS valve 22 HSS, PPC charge valve HSS pump 23 PPC relief valve HSS pump...
Page 228: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) REPLACE POWER TRAIN OIL FILTER ELEMENT ..................4-574 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER) ............................
Page 229 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 500 HOURS SERVICE REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITHOUT ADDITIONAL FUEL FILTER CARTRIDGE)..............................4-554 REPLACE POWER TRAIN OIL FILTER ELEMENT..................4-574 REPLACE HYDRAULIC TANK BREATHER ELEMENT .................. 4-584 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ........4-594 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED WIHH MACHINES) ......
Page 230 MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Perform the following maintenance only after the first 250 hours. q Replace power train oil filter element q Change oil in power train case, wash strainers (power train pump strainer, scavenging pump strainer) q Change oil in final drive case q Replace charge filter element q Change oil in hydraulic tank, replace hydraulic oil filter element.
Page 231 MAINTENANCE SERVICE PROCEDURE WHEN REQUIRED CLEAN INSIDE OF COOLING SYSTEM WARNING q Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to drain the coolant in this condition, there is a hazard of burns.
Page 232 MAINTENANCE SERVICE PROCEDURE When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mix- ing table given below. It is actually better to estimate and temperature about 10°C lower when deciding the mixing ratio. The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (anti- freeze/total amount of coolant x 100).
Page 233 MAINTENANCE SERVICE PROCEDURE 9. To remove air in the cooling system, run the engine for 5 minutes at low idle, then for 5 minutes at high idle. (While doing this, leave the radiator cap removed.) 10. Drain the coolant inside sub-tank (5), flush the inside of sub-tank (5), then add coolant to between the FULL and LOW marks.
Page 234 MAINTENANCE SERVICE PROCEDURE CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING q Always wear protective glasses, dust mask, or other protective equipment. q When removing the air cleaner element from the air cleaner body, it is dangerous to pull it out by force. When working at high places or where the foothold is poor, be careful not to fall because of the reac- tion when pulling out the outer element.
Page 235 MAINTENANCE SERVICE PROCEDURE 4. Use a clean cloth or brush to remove the dirt stuck to the cover and the inside of the air cleaner body. 5. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm²) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside.
Page 236 MAINTENANCE SERVICE PROCEDURE CHECK ELECTRICAL INTAKE AIR HEATER Check before the cold season starts (once a year). Remove the electric heater from the engine intake manifold and check for wire disconnections and dirt clinging to When checking and installing the electric heater, replace its gasket with a new one. CHECK AND ADJUST TRACK TENSION The wear of pins and bushings on the undercarriage will vary with the working conditions and types of soil.
Page 237 MAINTENANCE SERVICE PROCEDURE ADJUSTMENT WARNING Grease inside the adjusting mechanism is under high pressure. Grease coming from plug (1) under pressure can penetrate the body, causing injury or death. For this rea- son, do not loosen plug (1) more than one turn. Do not loosen any part other than plug (1).
Page 238 MAINTENANCE SERVICE PROCEDURE WHEN LOOSENING TENSION WARNING It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. 1. Remove 2 bolts (3), then remove cover (2). NOTICE q The safety label is stuck on the back of cover (2), so be careful not to damage the safety label.
Page 239 MAINTENANCE SERVICE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. METHOD OF TIGHTENING SHOE BOLT 1. First, tighten to a tightening torque of 588 ± 58.8 N·m (60 ± 6 kgf·m), then check that the nut and shoe are in tight contact with the mating face of the link.
Page 240 MAINTENANCE SERVICE PROCEDURE REVERSE AND REPLACE THE END BITS AND CUTTING EDGES WARNING It is dangerous if the work equipment moves by mistake when the cutting edges and end bits are being reversed or replaced. Set the work equipment in a stable condition, then stop the engine and lock the blade control lever securely with the work equipment lock lever.
Page 241 MAINTENANCE SERVICE PROCEDURE If bolt (2) and nut (1) are damaged, replace them with new ones at the same time. Loosen nut (1) remove bolt (2), then replace or turn. 6. Install the cutting edge on the blade and tighten the bolt temporarily.
Page 242 MAINTENANCE SERVICE PROCEDURE CLEAN AND CHECK RADIATOR FINS WARNING For the cleaning and check, stop the engine without fail and confirm that the fan is not rotating, and carry out the work. Be sure to close the radiator grille before turning the radiator fan so that no one will touch the turning fan carelessly.
Page 243 MAINTENANCE SERVICE PROCEDURE REPLACE AIR CONDITIONER BELT 1. Loosen 4 bolts (1) and jack bolt (2), then move compressor (3) to the side. 2. Replace the V-belt. q When adjusting the V-belt, do not push the compres- sor directly with the bar. Use jack bolt (2). 3.
Page 244 MAINTENANCE SERVICE PROCEDURE CLEAN AND CHECK HYDRAULIC COOLER FINS If the hydraulic cooler fins are clogged or there is dirt caught in the fins, clean and check the fins. 1. Loosen 4 bolts (2) of cover (1) at the left side face of the radiator guard, then remove cover (1).
Page 245 MAINTENANCE SERVICE PROCEDURE CLEAN, CHECK AIR CONDITIONER CONDENSER FINS If the air conditioner fins become clogged, clean and inspect. 1. Open the engine side cover on the right side of the machine. 2. Use compressed air to blow off all the mud, dirt, and leaves clogging fins (1).
Page 246 MAINTENANCE SERVICE PROCEDURE ADJUST IDLER CLEARANCE The idler moves to the front and rear under external force. When this happens, guide plate (2) becomes worn. It guide plate (2) becomes worn, the idler will slip to the side or tilt at an angle.
Page 247 MAINTENANCE SERVICE PROCEDURE CHECK UNDERCARRIAGE OIL Stop the machine on level ground, and check for any reduction in the oil in the idler (portion P), track roller (portion Q), bogie shaft (portion S), and carrier roller (portion R). 1. Loosen seal bolt (1) slowly and check if oil oozes out from the thread.
Page 248 MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) Clean the air conditioner air filter if it becomes clogged or if there is dirt or oil stuck to it. 1. Open inspection cover (1) on top of the hood, then remove pressure air filter (2).
Page 249 MAINTENANCE SERVICE PROCEDURE CHECK AND ADJUST AIR CONDITIONER (Machines equipped with cab) CHECK TENSION OF COMPRESSOR BELT If the belt is loose, it will slip and will not be able to carry out cooling properly. Compressor pulley Check the belt tension from time to time. The deflection should be 10 mm when pressed at a point midway between the drive pulley and compressor pulley with a finger force of approx.
Page 250 MAINTENANCE SERVICE PROCEDURE LUBRICATE DOOR HINGE If the door makes a squeaking noise when it is opened or closed, spray lubricant in through the split in the hinge bushing. If the bushing is worn, replace the hinge. CHECK DOOR LATCH WARNING If the control lever is touched by accident during checking, the machine moves off suddenly, and this may lead to seri-...
Page 251 MAINTENANCE SERVICE PROCEDURE REPLACE DOOR DAMPER If the depth of the door damper rubber groove is less than 2 mm, replace the damper. There are two dampers each at the top and bottom on the left Less than 2 mm and right doors.
Page 252 MAINTENANCE SERVICE PROCEDURE REPLACEMENT FRONT, REAR WIPER 1. It is hooked at portion (A), so move the blade in the direc- tion of the arrow to remove it. 2. Install the new blade and hook it securely. REAR WIPER 1. Remove E-ring (1). The blade can then be removed.
Page 253 MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT See “OPERATIONS AND CHECKS AFTER STARTING ENGINE (3-93)“. 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 254 MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT WARNING q The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting. If the pressure is not released, high pressure oil may spurt out and cause serious personal injury.
Page 255: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see “CHECK BEFORE STARTING (3-71)“. q Check monitor panel q Check coolant level, add coolant q Check fuel level, add fuel q Check water separator, drain water and sediment q Drain water, sediment from fuel tank q Check oil level in engine oil pan, add oil q Check oil level in power train case, add oil...
Page 256: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE LUBRICATING 1. Lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3. After greasing, wipe off any old grease that was pushed out. q Grease equalizer bar side pin (4 places) Left and right sides of machine: 2 places each 1) Remove all soil and mud from the top of track frame and...
Page 257 MAINTENANCE SERVICE PROCEDURE q Grease equalizer bar center pin (1 place) 1) Open the engine side cover on the left of the machine, then remove 2 bolts (1). 2) Pull hinged cover (2) and open. 3) Pump in grease through the grease fitting marked by the arrow.
Page 258 MAINTENANCE SERVICE PROCEDURE q Power tiltdozer Lift cylinder support yoke (4 places) Tilt cylinder ball joint (1 place) Lift cylinder support shaft (2 places) Tilt brace ball joint (1 place) Blade arm (2 places) Blade center link (1 place) 4-48...
Page 259 MAINTENANCE SERVICE PROCEDURE q Angledozer Lift cylinder support yoke (4 places) Tilt brace thread (2 places) Lift cylinder support shaft (2 places) q Ripper (1) Tilt cylinder bottom pin (2 places) (2) Lift cylinder bottom pin (2 places) (3) Tilt cylinder rod end pin (2 places) (4) Lift cylinder rod end pin (2 places) (5) Arm pin (front) (2 places) (6) Arm pin (rear) (2 places)
Page 260 MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. 1. Stop the machine so that drain plug (1) is at the bottom. 2.
Page 261 MAINTENANCE SERVICE PROCEDURE WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is possible to check the electrolyte level from the side of the battery, check as follows. 1. Use a wet cloth to clean the area around the electrolyte level lines and check that the electrolyte level is between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines.
Page 262 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 263 MAINTENANCE SERVICE PROCEDURE CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST CHECKING The standard deflection for the drive belt is approx.13 to 16 mm when pressed by thumb (approx.10 kg) at a point midway Alternator pulley between the drive pulley and alternator pulley. Drive pulley ADJUSTING 1.
Page 264 MAINTENANCE SERVICE PROCEDURE CHECK BRAKE PERFORMANCE WARNING If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately. NOTICE Do not place the joystick in the 1st speed position. Otherwise, it will cause damage to the machine. Before starting the engine, check that the area around the machine is safe, then do as follows: 1.
Page 265: Every 500 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 500 HOURS SERVICE Maintenance for every 250 hours should be performed at the same time. REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITHOUT ADDITIONAL FUEL FILTER CAR- TRIDGE) WARNING q After the engine has been operated, all parts are at high temperature, so do not replace the filter imme- diately.
Page 266 MAINTENANCE SERVICE PROCEDURE 4. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/ 4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
Page 267 MAINTENANCE SERVICE PROCEDURE REPLACE POWER TRAIN OIL FILTER ELEMENT 1. Open the engine side cover on the left side of the machine, remove bolt (1) then open cover (2) to the outside using the bottom hinge as a pivot. 2. Remove mounting bolt (4) of filter (3), then remove cover (5).
Page 268 MAINTENANCE SERVICE PROCEDURE REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING Replace the element when the oil is cold. When removing breather cap (1), turn it slowly to release the internal pressure before removing it. 1. Remove breather cap (1) on the top of the hydraulic tank. 2.
Page 269 MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE WARNING The oil is at high temperature after the engine has been operated, so never change the oil immediately after finishing operations. Wait for the oil to cool down before changing it. q Oil replacement amount: 37 liters q Prepare a socket wrench and filter wrench.
Page 270 MAINTENANCE SERVICE PROCEDURE 2. Taking care not to get oil over yourself, remove drain plug (P) slowly, then loosen drain valve (2) and drain the oil. Be careful not to loosen the drain valve too much and deform the stopper pin inside the valve. 3.
Page 271 MAINTENANCE SERVICE PROCEDURE REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED WITH MACHINES) WARNING q After the engine has been operated, all parts are at high temperature, so do not replace the filter imme- diately. Wait for all parts to cool down before starting the operation. q High pressure is generated inside the engine fuel piping system when the engine is running.
Page 272 MAINTENANCE SERVICE PROCEDURE NOTICE q When adding fuel, do not remove cap (B). Always add fuel from the 8 small holes (A) on the dirty side. q After adding fuel, remove cap (B) and install the fuel fil- ter. q Always fill with clean fuel. Be careful not to let any dirt or dust get into the fuel.
Page 273 MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 250 and 500 hours should be performed at the same time. CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENG- ING PUMP STRAINER) WARNING q The oil is at high temperature immediately after operations, so wait for the temperature to go down before starting the operation.
Page 274: Replace Power Train Oil Filter Element
MAINTENANCE SERVICE PROCEDURE 7. Loosen mounting bolt (10) of the scavenging pump strainer, then remove cover (11). Portion P 8. Remove strainer (12). 9. Remove any dirt stuck to strainer (12), then wash it in clean diesel oil or flushing oil. Wash the removed parts and the inside of the case at the same time.
Page 275: Wash Power Train Case Breather
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN FINAL DRIVE CASE WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. q Oil replacement amount: 58 liters 1.
Page 276: Lubricate Universal Joint
MAINTENANCE SERVICE PROCEDURE LUBRICATE UNIVERSAL JOINT WARNING The undercover is heavy. Never try to open or close the cover when directly beneath it. When removing bolts (2), carry out the work from the rear of the cover so that you can easily get out of the way.
Page 277: Check Tightening Parts Of Turbocharger
MAINTENANCE SERVICE PROCEDURE CHECK TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked. CHECK, CLEAN FUEL STRAINER 1. Tighten fuel supply valve (1) at the bottom of the fuel tank, remove cap (2), then wash the strainer and strainer case. The strainer forms one unit with the cap.
Page 278: Replace Charge Filter Element
MAINTENANCE SERVICE PROCEDURE REPLACE CHARGE FILTER ELEMENT 1. Loosen mounting bolts (1), then remove inspection cover (2). 2. Loosen mounting bolts (3), then remove filter cover (4). 3. Remove drain plug (P) (which can be seen from under the fender) and drain the oil. 4.
Page 279: Cartridge)
MAINTENANCE SERVICE PROCEDURE REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITH ADDITIONAL FUEL FILTER CAR- TRIDGE) WARNING q After the engine has been operated, all parts are at high temperature, so do not replace the filter imme- diately. Wait for all parts to cool down before starting the operation. q High pressure is generated inside the engine fuel piping system when the engine is running.
Page 280 MAINTENANCE SERVICE PROCEDURE 4. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/ 4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
Page 281: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 250, 500, and 1000 hours should be performed at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before changing the oil.
Page 282: Clean Engine Breather Element
MAINTENANCE SERVICE PROCEDURE 4. Remove mounting bolts (7) of hydraulic oil filter (6), then remove cover (8). 5. Remove drain plug (3) that can be seen from under the fender and drain the oil between there and the oil filter case.
Page 283: Change Oil In Damper Case, Clean Damper Breather
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER WARNING q The oil is at high temperature immediately after the machine has been operated.Wait for the oil to cool down before carrying out maintenance. q The undercover is heavy. Do not go directly under the cover when opening or closing it. When remov- ing bolts (4), carry out the operation at the rear of the point immediately under the cover so that it is possible to escape at any time.
Page 284: Check Pivot Bearing Oil Level, Add Oil
MAINTENANCE SERVICE PROCEDURE 5. Lower cover (2) gradually to open it. Drain plug (P) can be seen at the top. 6. Remove dipstick (G), then remove drain plug (P) and drain the oil. After draining the oil,tighten drain plug (P). 7.
Page 285: Every 4000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 4000 HOURS SERVICE Maintenance for every 250, 500, 1000, and 2000 hours should be performed at the same time. CHECK PLAY OF TURBOCHARGER ROTOR Contact your Komatsu distributor to have the rotor play checked. CLEAN, CHECK TURBOCHARGER CHECK ENGINE VALVE CLEARANCE, ADJUST As special tools is required for removing and adjusting the parts, you should request service from your Komatsu distributor.
Page 286: Checking For Looseness Of High-Pressure Clamp, Hardening Of Rubber
MAINTENANCE SERVICE PROCEDURE CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER Check for any looseness in the high-pressure clamp mounting bolts (1) to (15) in the drawing in the illustrations below. Check visually and feel with your finger to check that the rubber has not hardened. If there is any problem, the problem part must be replaced.
Page 287: Checking For Missing Fuel Spray Prevention Cap, Hardening Of Rubber
MAINTENANCE SERVICE PROCEDURE CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER Fuel spray prevention caps (1) - (16) and fuel spray prevention cover (17) are protective parts installed to prevent fire caused by fuel leaking and spraying out on to high temperature parts of the engine. Check visually that there are no missing caps or loose bolts, and feel with your finger to check that the rubber has not hardened.
Page 288: Every 8000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 8000 HOURS SERVICE Maintenance for every 10, 100, 250, 500, 1000, 2000, and 4000 hours of service should be performed at the same time. REPLACE INJECTOR NOZZLE TIP Contact your Komatsu distributor to have the injector nozzle assembly replaced. REPLACE HIGH-PRESSURE PIPING CLAMPS Contact your Komatsu distributor to have the engine high-pressure clamps replaced.
Page 289 SPECIFICATIONS...
Page 290 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Item Unit D155AX-5 Operating weight 39,500 *1 (without operator) Blade (straight tiltdozer) 4,900 Unit weight (including cylinder) Ripper unit weight 3,710 Name of engine Komatsu SA6D140E-3 diesel engine Engine horsepower kW (HP)/rpm 231(310)/1,900 Overall length 8,155 Overall height...
Page 291 ATTACHMENTS, OPTIONS WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 292 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 293 ATTACHMENTS, OPTIONS INTRODUCTION OF ATTACHMENTS AND OPTIONS INTRODUCTION OF ATTACHMENTS AND OPTIONS INTRODUCTION OF ATTACHMENTS AND OPTIONS Name Specifications, use Wide shoe width 610 mm Wide shoe width 660 mm Track shoes Wide shoe width 710 mm Heavy-duty shoe width 610 mm Heavy-duty shoe width 660 mm...
Page 294 ATTACHMENTS, OPTIONS HEADREST, HANDLING HEADREST, HANDLING Use the headrest fully pushed in to the lowest position.
Page 295 ATTACHMENTS, OPTIONS CAP WITH LOCK, HANDLING CAP WITH LOCK, HANDLING METHOD OF OPENING AND CLOSING CAP WITH LOCK Lock-type caps are available for the radiator water filler, fuel tank filler cap, power train case oil filler cap, hydraulic tank oil filler cap, and hydraulic tank breather cap. The method of opening or closing the cap is as follows: TO OPEN THE CAP 1.
Page 296 ATTACHMENTS, OPTIONS PROCEDURE FOR SELECTING RIPPER POINT PROCEDURE FOR SELECTING RIPPER POINT PROCEDURE FOR SELECTING RIPPER POINT Procedure (1) Install standard point A Procedure (2) No (less than 70%) Is there a high propotion Check wear Is wear rapid? of quartz in rock? Excessice generation of heat from point (only tip of point wears) (Whole point...
Page 297 INDEX...
Page 298 INDEX...
Page 299 INDEX INDEX <A> <G> ACCUMULATOR, HANDLING......3-68 GENERAL PRECAUTIONS......2-11,6-2 ADJUSTING POSTURE OF WORK EQUIPMENT.. 3- PRECAUTIONS RELATED TO SAFETY..6-2 GENERAL VIEW ........... 3-2 AIR CONDITIONER ..........3-61 GENERAL VIEW OF CONTROLS AND GAUGES GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ..........
Page 300 INDEX <P> STARTING NEGINE ..........3-88 STEERING MACHINE ........3-104 PARKING MACHINE .........3-108 STOPPING ENGINE ........... 3-95 PERIODIC REPLACEMENT OF SAFETY CRITICAL STOPPING MACHINE......... 3-98 PARTS.............4-16 SWITCHES............3-32 POSITION OF SERVICE METER......1-12 POWER SOURCE ..........3-44 PRECAUTIONS FOR LOADING .......3-130 <T> PRECAUTIONS FOR MAINTENANCE ....2-30 TABLE TO ENTER SERIAL NO.
Page 301 COLOPHON...

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Komatsu Utility D155AX-5 Operation & Maintenance Manual

Foreword

Foreword

Safety Information

Introduction

Necessary Information

Safety

Safety Labels

General Precautions

Precautions for Operation

Precautions for Maintenance

Explanation of Components

Operation

Transportation

Cold Weather Operation

Long-Term Storage

Troubleshooting

Maintenance

Guides to Maintenance

Outlines 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

Every 500 Hours Service 4

Every 500 Hours Service

Every 2000 Hours Service

Every 4000 Hours Service

Every 8000 Hours Service

Quick Links

Chapters

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Summary of Contents for Komatsu Utility D155AX-5