Page 1 Operation & EENAM03560 Maintenance Manual D51EX- D51PX- BULLDOZER SERIAL NUMBER D51EX-24 - 10001 and up D51PX-24 - 10001 and up WARNING Unsafe use of this machine may cause serious injury or ORIGINAL INSTRUCTIONS death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 3 Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4 Operation and Maintenance Manual in the steel box on the back of the seat. If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 5 FOREWORD READ THIS MANUAL complies with the applicable standards and regulations of your country, consult your Komatsu distributor before operating the machine.
Page 6: Safety Information
SAFETY INFORMATION FOREWORD SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 7: Noise
FOREWORD NOISE NOISE Two labels indicating the machine noise level are affixed on the machine. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator’s position is 2.5dB, in accordance with ISO 11201...
Page 8: Vibration Levels
VIBRATION LEVELS FOREWORD VIBRATION LEVELS When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper- ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 9 FOREWORD VIBRATION LEVELS • Do not jump down from the cab or machine • Do not repeatedly handle and lift loads...
Page 10: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Dozing work • Leveling work • Cutting into hard or frozen ground or ditching • Works of felling trees and removing stumps For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS”.
Page 11: Engine Technology To Conform Exhaust Gas Emission
Diesel Exhaust Fluid is the aqueous urea solution for the SCR system. The Komatsu Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the ex- haust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decom- poses the nitrogen oxides into nitrogen and water.
Page 12: Product Information
PRODUCT INFORMATION FOREWORD PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE It is located at front left of the operator's seat.
Page 13: Fluorinated Greenhouse Gases
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: KOMATSU LTD. Address: 2-3-6 Akasaka Minato-ku, Tokyo 107-8414 Japan Authorised representative: KOMATSU EUROPE INT. Address: Mechelsesteenweg 586 B-1800 Vilvoorde Belgium Distributor name Address Service personnel Phone/Fax 1-11...
Page 14: Serial Plate
SERIAL PLATE FOREWORD SERIAL PLATE EI000001 MACHINE DESIGNATION/TYPE ENGINE POWER SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER YEAR OF CONSTRUCTION MANUFACTURER OPERATING MASS AUTHORISED REPRESENTATIVE 1-12...
Page 15: Declaration Of Conformity
FOREWORD DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY The manufacturer/Authorised representative The manufacturer Authorised representative KOMATSU LTD. KOMATSU EUROPE INT. 2-3-6 Akasaka Mechelsesteenweg 586 Minato-ku, Tokyo 107-8414 B-1800 Vilvoorde Japan Belgium Declares that this machine: D51EX-24 D51PX-24 Fulfils all the relevant provisions of following EC Directives:...
Page 16: Table Of Contents
TABLE OF CONTENTS FOREWORD TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 SAFETY INFORMATION .......................... 1-4 NOISE............................... 1-5 VIBRATION LEVELS ..........................1-6 VIBRATION - OPERATING CONDITION ................... 1-6 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-6 INTRODUCTION ............................1-8 MAIN USE OF MACHINE ........................
Page 17 TROUBLES AND ACTIONS ......................... 3-208 PRECAUTIONS FOR TOWING MACHINE ..................3-208 PRECAUTIONS FOR DISCHARGED BATTERY ................3-209 OTHER TROUBLE......................... 3-215 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 1-15...
Page 18 TABLE OF CONTENTS FOREWORD KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................4-2 PRECAUTIONS FOR REFILLING OIL OR FUEL ................4-2 PRECAUTIONS FOR ADDING DEF ....................4-2 WELDING INSTRUCTIONS.......................
Page 19 CONSUMABLE PARTS LIST ......................7-3 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-4 LUBRICATION CHART ........................7-4 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-7 INDEX................................8-1 1-17...
Page 21: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 22: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 23: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS (1) Caution for operation, inspection and maintenance (9) Stop rotation during inspection and maintenance (2) Caution for safety at rear (10) Caution for approaching while moving machine (3) Caution when leaving operator's seat (11) Prohibition of start by short-circuiting (4) Caution for high-temperature coolant (12) Caution for handling ROPS/FOPS...
Page 24: Contents Of Safety Labels
SAFETY LABELS SAFETY CONTENTS OF SAFETY LABELS Caution for operation, inspection and maintenance “09651-A0481” • Warning! • Read manual before operation, maintenance, disassembly, assembly and transportation. Caution for safety at rear “09802–B0480” • Sign indicates a hazard of rear working and advancing be- hind.
Page 25 SAFETY SAFETY LABELS Caution for high-temperature coolant “09653-A0481” • Never remove the cap when the engine is at operating (high) temperature. Steam or high temperature oil blowing up from the radiator or hydraulic tank, will cause personal injury and/or burns. •...
Page 26 SAFETY LABELS SAFETY Caution for handling cable “09808-A0881” • Sign indicates an electric hazard from handling the cable. • Read manual for safe and proper handling. Stop rotation during inspection and maintenance “09667-A0481” • Sign indicates a hazard of rotating parts, such as belt. •...
Page 27 SAFETY SAFETY LABELS Prohibition of start by short-circuiting “09842-A0642” • Start the engine only after sitting down in the operator’s seat. • Do not attempt to start the engine by shot-circuiting the en- gine starting circuit. Such an act may cause a serious bodi- ly injury or fire.
Page 28 SAFETY LABELS SAFETY Caution for handling DEF “09632-61480” • DEF Only. To avoid engine damage or fire, fill with DEF only. • Never use diesel fuel. Caution for handling seat belt “09848-A0480” • Always use seat belt when operating the machine to re- duce risk of injury or death in case of a roll-over.
Page 29: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 30: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical compo- nents.
Page 31 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • After a fire, harmful compounds may be left. If it touches your skin, it may have a bad influence on your body. Be sure to wear rubber gloves when handle the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).
Page 32: Precautions When Getting On Or Off Machine
In addition, tighten any loose bolt of the handrails and steps. If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu dis- tributor to perform this work. •...
Page 33 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it. LIFTING OF PERSONNEL PROHIBITED Under no circumstances should this machine be used for the lifting of personnel.
Page 34: Do Not Get Caught In Work Equipment
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 35: Precautions When Running Engine Inside Building
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING The engine exhaust gas contains substances that may damage your health or even cause death. Start or operate the engine in a place where there is good ventilation. If the engine or ma- chine must be operated inside a building or underground, where the ventilation is poor, take steps to ensure that the en- gine exhaust gas is removed and that ample fresh air is...
Page 36: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 37 SAFETY PRECAUTIONS FOR OPERATION Voltage of Cables Safety Distance 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body. •...
Page 38: Start Engine
Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!”...
Page 39 SAFETY PRECAUTIONS FOR OPERATION • Before starting the engine, check that work equipment lock lever (1) and parking brake lever (2) are in LOCK positions (L). • Adjust the mirrors to have a good rear view from the oper- ator's seat. •...
Page 40: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly, the machine will be unable to display its full perform- ance. It is dangerous and may cause serious personal injury or death. When performing the checks, move the machine to a wide area with no obstructions, and pay careful attention to the surroundings.
Page 41 SAFETY PRECAUTIONS FOR OPERATION • When driving the machine on a level ground, keep the work equipment at height (A) of 40 to 50 cm above the ground. If that height is not maintained between the work equipment and the ground, the work equipment may get stuck in the ground and the machine may tip over.
Page 42 PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN OPERATING MACHINE • Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when dropping soil over a cliff, dump one pile, then use the next pile of soil to push the first pile. •...
Page 43: Precautions For Transportation
• This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is wrong when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 44: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY TOWING AND BEING TOWED PRECAUTIONS FOR TOWING AND BEING TOWED Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or death.
Page 45: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 46 END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 47 SAFETY PRECAUTIONS FOR MAINTENANCE • Rotating parts such as the fan, fan belt are dangerous that they may easily catch a body part or an object someone wears. Be careful not to come close to the rotating part. • Never drop or insert tools or other objects into the fan, fan belt, or other rotating parts.
Page 48: Precautions For Check And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT Machine or work equipment may fall, and it is dangerous that serious personal injury or death may occur. Al- ways observe the following. • Make sure the hoists or hydraulic jacks you use are in good condition and strong enough to handle the weight of the component.
Page 49 SAFETY PRECAUTIONS FOR MAINTENANCE HANDLE BATTERY Before inspecting or handling the battery, turn the key in the starting switch to OFF position and check that the system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key. Danger of battery exploding When the battery is being charged, flammable hydrogen gas is generated and may explode.
Page 50 PRECAUTIONS FOR MAINTENANCE SAFETY • If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, pieces might be scattered, and it may cause serious personal injury or death. Always wear protective eyeglasses and gloves. •...
Page 51 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 52 If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. If it is necessary to disassemble it, ask your Komatsu distributor to perform the work. HANDLE ACCUMULATOR This machine is equipped with an accumulator.
Page 53 Do not hit or roll it, or subject it to any impact. • When disposing of the accumulator, the gas must be re- leased. Ask your Komatsu distributor to perform this work. PRECAUTIONS FOR COMPRESSED AIR • When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by flying dust or particles.
Page 54 PRECAUTIONS FOR MAINTENANCE SAFETY • The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious personal injury or death. It is difficult to judge the remaining life of these components from external inspection or the feeling when operating, so always replace them at the specified interval.
Page 55: Precautions For Def
SAFETY PRECAUTIONS FOR DEF PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 57: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 58: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Blade (7) Work equipment frame (2) Front cover (8) Angle cylinder (3) ROPS cab (9) Track frame (4) Sprocket (10) Track (5) Lift cylinder (11) Radiator grille (6) Idler (12) Tilt cylinder (13) DEF pump (15) Battery disconnect switch (14) DEF tank...
Page 59: Controls And Gauges Names
OPERATION GENERAL VIEW (17) Komatsu Closed Crankcase Ventilation (hereafter (19) SCR KCCV) ventilator (18) DEF injector CONTROLS AND GAUGES NAMES (1) Air conditioner switch (10) Starting switch (2) Cigarette lighter (11) Decelerator/brake pedal (3) Fuel control dial (12) Blade control lever...
Page 60 GENERAL VIEW OPERATION MACHINE MONITOR EQUIPMENT NAME AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Pedal mode selector switch (17) Steering mode display (2) Buzzer cancel switch (18) Preheating pilot lamp (3) Operating mode selector switch (19) Fan reverse rotation pilot lamp (4) Reverse travel speed setting switch (20) FLOAT mode pilot lamp...
Page 61: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen (1) Warning display...
Page 62 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION • When the starting switch is turned to ON position, opening screen GG is displayed. • After opening screen GG is displayed for 2 seconds, the screen switches to camera image FF. •...
Page 63 End screen when any message has been re- ceived If there is any message from your Komatsu distributor, it is dis- played on the end screen. In this case, turn the starting switch to ON position to re-check the message, and if the message is requesting a response, make a reply to it.
Page 64 F1, and the screen changes to the Check Before Starting screen BB without inputting ID number. REMARK • Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identifica- tion function. • Depending on the set value of ID holding time, even if in-...
Page 65 Be careful not to use it for the purpose of security enhance- ment. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person.
Page 66 EXPLANATION OF COMPONENTS OPERATION If there is any abnormality currently generated, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the current abnormality. The “Current Abnormality” screen is displayed. BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any abnormality occurs during operation, the standard screen AA changes to the abnormality screen EE.
Page 67 OPERATION EXPLANATION OF COMPONENTS If there is any error existing, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the current abnormality. The “Current Abnormality” screen is displayed. WARNING DISPLAY NOTICE Appearance of any of action levels “L01” to “L04” on the machine monitor indicates presence of an ab- normality of the machine.
Page 68 EXPLANATION OF COMPONENTS OPERATION (1) Action level display (6) Engine speed caution lamp (*) (2) Caution lamp (7) DEF level caution lamp (3) Caution lamp (8) Fuel level caution lamp (4) Hydraulic oil temperature caution lamp (9) Caution lamp (5) Engine coolant temperature caution lamp (*): Displayed items change according to setting of the multi-gauge.
Page 69 │ no load or stop it. Sounds inter- Lights up in │ mittently If the condition is not improved, ask your Komatsu distributor │ for inspection and maintenance. │ Some functions may be restricted from use, but the machine ↓...
Page 70 EXPLANATION OF COMPONENTS OPERATION CAUTION LAMP LIST NOTICE • These caution lamps do not guarantee the condition of the machine. Do not simply rely on the caution lamp when performing checks before starting (start-up inspec- tion). Always get off the machine and check each item directly. •...
Page 71 OPERATION EXPLANATION OF COMPONENTS Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Abnormal Abnormal Regeneration performance cau- tion lamp (L03) (L01) Abnormal Sensing is DEF level caution lamp Normal disabled (L04, L03) Abnormal Abnormal DEF system caution lamp (L04, L03) (L01)
Page 72 EXPLANATION OF COMPONENTS OPERATION Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Clogged Air cleaner clogging caution lamp (L01) Due time is Maintenance time caution lamp Notice over Seat belt is Seat belt caution lamp not fastened For the meaning of each caution lamp and the action to take for it, see the section of each caution lamp.
Page 73 OPERATION EXPLANATION OF COMPONENTS F1: Displays the next page. When on the last page, it displays the first page. F2: Displays the previous page. When on the first page, it dis- plays the last page. F5: Returns the screen to the standard screen. ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature.
Page 74 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 75 The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, and then ask your Komatsu distributor for the inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 76 EXPLANATION OF COMPONENTS OPERATION Stop the operation, move the machine to a safe place, and then ask your Komatsu distributor for the inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow. Some functions may be restricted from use, but the machine can operate.
Page 77 It is not necessary to stop the machine immediately. However, it is recommended to inspect the machine for maintenance after you finish operations. Ask your Komatsu distributor for inspection and maintenance as necessary. REGENERATION PERFORMANCE CAUTION LAMP This warns about the deterioration of regeneration performance of aftertreatment devices.
Page 78 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the work, move the machine to a safe place, and then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 79 OPERATION EXPLANATION OF COMPONENTS Move the machine to a safe area and stop the machine, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” appears on screen. The caution lamp comes on in yellow. It is not necessary to stop the machine immediately.
Page 80 The alarm buzzer sounds intermittently. Charging is not performed normally while the engine is running. Stop the engine and check the alternator drive belt for damage, and then ask your Komatsu distributor for inspection and main- tenance. WATER SEPARATOR CAUTION LAMP The water separator caution lamp warns that water is accumu- lated in the water separator.
Page 81 • The lighting time of maintenance due time notice (yellow) has been initially set to 30 hours, but it can be changed. To change the setting, ask your Komatsu distributor. • For operations on the “Maintenance” screen, see “MAIN- TENANCE SCREEN SETTING”.
Page 82 EXPLANATION OF COMPONENTS OPERATION PILOT DISPLAY AND METER DISPLAY Pilot display (1) Engine stop pilot lamp (8) Preheating pilot lamp (2) Parking brake pilot lamp (9) Fan reverse pilot lamp (3) Work equipment lock pilot lamp (10) FLOAT mode pilot lamp (4) Aftertreatment devices regeneration display (11) Blade mode display (5) Message display...
Page 83 ON position. MESSAGE DISPLAY The User Message is displayed when there is a message from Komatsu. To read the message, see “MESSAGE DISPLAY”. Lights up in green (A): There is unread message. Lights up in blue (B): There is any read message to which no reply has been made.
Page 84 EXPLANATION OF COMPONENTS OPERATION AFTERTREATMENT DEVICES REGENERATION DISPLAY This displays the regeneration status and automatic regenera- tion setting status of the aftertreatment devices. (A): Comes on during regeneration. (B): Comes on when setting automatic regeneration disable. WORK EQUIPMENT LOCK PILOT LAMP The work equipment lock pilot lamp lights up when the work equipment lock lever is in LOCK position.
Page 85 OPERATION EXPLANATION OF COMPONENTS BLADE MODE DISPLAY The currently set blade mode is displayed on the blade mode display. The display of the blade mode is as follows. (A): For fast operation Lights up when it is set to FAST mode. (B): For general operation Lights up when it is set to NORMAL mode.
Page 86 EXPLANATION OF COMPONENTS OPERATION Hydraulic relief deterrence guidance If the hydraulic oil is kept relieved for more than 10 seconds during operation, the hydraulic relief deterrence message is displayed on the machine monitor. The hydraulic relief deterrence message goes out 5 seconds later or when switch F5 is pressed.
Page 87 OPERATION EXPLANATION OF COMPONENTS When the time until engine power deration starts is less than 1 hour “DEF refill caution will appear soon.” is displayed. DEF low level guidance goes out in more than 15 seconds or when switch F5 is pressed. Add DEF to the DEF tank before engine power is to be derated.
Page 88 EXPLANATION OF COMPONENTS OPERATION In pedal mode, decelerator mode and brake mode are availa- ble. (H): Decelerator mode (I): Brake mode METER DISPLAY MULTI GAUGE The multi gauge can display various items. As an example, dis- play of the engine tachometer is explained below. If the indicator is in green range during operations, it is normal.
Page 89 OPERATION EXPLANATION OF COMPONENTS HYDRAULIC OIL TEMPERATURE GAUGE Hydraulic oil temperature gauge shows the hydraulic oil tem- perature. If the indicator is in green range during operations, it is normal. If the indicator goes beyond red range (A) during operations, the overheat prevention system operates.
Page 90 EXPLANATION OF COMPONENTS OPERATION SERVICE METER / CLOCK The service meter/clock shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even when the machine is not moving. The service meter advances 0.1 every 6 operation minutes, regardless of the engine speed.
Page 91 OPERATION EXPLANATION OF COMPONENTS ECO GAUGE / DRAWBAR PULL GAUGE The ECO gauge/ drawbar pull gauge displays ECO gauge (in- stantaneous fuel consumption) (C) or drawbar pull gauge (work load) (D). The instantaneous fuel consumption means the fuel consump- tion rate at each moment, which varies with the work load and engine speed.
Page 92 EXPLANATION OF COMPONENTS OPERATION REMARK • Immediately after turning the starting switch to ON position and while the engine is running, DEF level cau- tion lamp (1) lights up in white. However, this does not indicate abnormality. • In cold weather, DEF level cannot be detected and DEF level caution lamp (1) lights up in white for approxi- mately 1 hour.
Page 93 OPERATION EXPLANATION OF COMPONENTS (O) Switch F1: Customize switch (A) Switch F2: Multi-gauge selector switch (B) Switch F3: Camera image selector switch. (C) Switch F4: Service meter / clock display selector switch (D) Switch F5: Current Abnormality display switch (Only while caution lamp is lit) (E) Switch F5: Energy saving (ECO) guidance erase switch (While ECO guidance is displayed) (F) Switch F6: User menu display switch...
Page 94 EXPLANATION OF COMPONENTS OPERATION (I) Switch F3: Moves to the item below (forward). (When on the last line, it moves to the first line.) (J) Switch F4: Moves to the item above (backward). (When on the first line, it moves to the last line.) (K) Switch F5: Cancels any change and returns to the previous screen.
Page 95 OPERATION EXPLANATION OF COMPONENTS PEDAL MODE SELECTOR SWITCH The pedal mode selector switch is used to switch the pedal mode between decelerator mode and brake mode. If the decelerator/brake pedal is depressed in decelerator mode, the travel speed and engine speed lower. If the decelerator/brake pedal is depressed in brake mode, the travel speed lowers but the engine speed does not lower.
Page 96 EXPLANATION OF COMPONENTS OPERATION Press switch F1, and “Mode Select” screen is displayed. On “Mode Select” screen, you can set and save the following items as desired. Item Contents of setting Operating Mode Power/ Economy Gear Shift Mode Quick shift/ Variable shift Pedal Mode Decelerator mode/ Brake mode Reverse Travel...
Page 97 OPERATION EXPLANATION OF COMPONENTS PEDAL MODE Select “Pedal Mode” on “Mode Select” screen, and press switch F6. Pedal mode can be switched in accordance with the operation. Pedal mode can also be switched with the pedal mode selector switch. REVERSE TRAVEL SPEED SETTING Select “Reverse Travel Speed Setting”...
Page 98 EXPLANATION OF COMPONENTS OPERATION BLADE MODE Select “Blade Mode” on “Mode Select” screen, and press switch F6. Blade mode can be changed according to the operation. By setting to “FAST” mode, starting of operation for RAISE and LOWER becomes quick. By setting to “FINE”...
Page 99 OPERATION EXPLANATION OF COMPONENTS 2ND TRAVEL SPEED SETTING Select “2nd Travel Speed Setting” on “Mode Select” screen, and press switch F6. 2nd travel speed in quick shift mode can be selected out of 5 levels according to the operation. You can increase or decrease the speed in 2 levels each. +2: Increases 2 levels from preset 2nd travel speed +1: Increases 1 level from preset 2nd travel speed 0: Preset 2nd travel speed...
Page 100 EXPLANATION OF COMPONENTS OPERATION 3RD TRAVEL SPEED SETTING Select “3rd Travel Speed Setting” on “Mode Select” screen, and press switch F6. 3rd travel speed in quick shift mode can be selected out of 3 levels according to the operation. You can increase or decrease the speed in 1 level each. 0: Increases 1 level from preset 3rd travel speed -1: Preset 3rd travel speed -2: Decreases 1 level from preset 3rd travel speed...
Page 101 OPERATION EXPLANATION OF COMPONENTS Check the setting of each item (on the left of the screen). Press the switch F3 or F4 to move the yellow cursor to a memory number (“M1” to “M5”) to save, and press the switch F6. The setting is saved by the above operation.
Page 102 EXPLANATION OF COMPONENTS OPERATION Other mode operations while camera image is displayed Even when the camera image is displayed, it is possible to operate following modes. • It is possible to change the operating mode by pressing the operating mode selector switch. When the operating mode is changed, the screen returns automatically to the standard screen.
Page 103 OPERATION EXPLANATION OF COMPONENTS • Press the pedal mode selector switch to change the pedal mode. Actions against warning during camera image display If any error or warning occurs on the machine while the camera image is displayed, the caution lamp flashes at the top left of the screen.
Page 104 EXPLANATION OF COMPONENTS OPERATION SERVICE METER/CLOCK DISPLAY SELECTOR SWITCH By pressing switch F4, you can switch the service meter and clock display on the standard screen. If you press switch F4 while the clock is displayed, the service meter is displayed instead of the clock. If you press switch F4 while the service meter is displayed, the clock is displayed instead of the service meter.
Page 105 OPERATION EXPLANATION OF COMPONENTS METHOD FOR USING MULTI GAUGE The multi-gauge can display the following items. Multi-gauge selection item Remarks Engine speed There is a caution Machine speed Work equipment pump pressure Battery voltage There is a caution Drawbar pull Clock display An approximate value indicated by the multi-gauge is as fol- lows.
Page 106 When the pointer is in green range during operation, it is normal. If the pointer is in red range, charge during engine running is not performed normally. Stop the operation, move the machine to a safe place, and then ask your Komatsu distributor for the inspection and maintenance.
Page 107 OPERATION EXPLANATION OF COMPONENTS USER MENU DISPLAY SWITCH On the standard screen, press switch F6 to display the user menu screen on which you can make various settings for the machine in the monitor display. USER MENU The user menu consists of the following kinds. Press switches F1 and F2 to move to right and left for selecting menu screens.
Page 108 EXPLANATION OF COMPONENTS OPERATION (b) “Machine Setting” • Fan reverse mode • Auto idle stop timer setting (c) “Aftertreatment Devices Regeneration” • Setting for regeneration disable • Operation of manual stationary regeneration (d) “SCR Information” • Check of DEF level •...
Page 109 OPERATION EXPLANATION OF COMPONENTS (g) Mail Check • Check of mail contents and reply to mail Operation on user menu screen On the user menu screen, it is possible to perform the following operations with switches F1 to F6. F1: Moves to the left menu. When on the left end menu, it moves to the right end menu.
Page 110 EXPLANATION OF COMPONENTS OPERATION ENERGY SAVING GUIDANCE Each item of “Energy Saving Guidance” menu (a) is used for displaying and setting the notification relevant to energy saving. CHECK OPERATION RECORDS Select “Operation Records” (1) from “Energy Saving Guidance” menu screen, then press switch F6. On “Operation Records”...
Page 111 OPERATION EXPLANATION OF COMPONENTS CHECK ECO GUIDANCE RECORD Select “ECO Guidance Records” (2) from “Energy Saving Guid- ance” screen, then press switch F6. On the “ECO Guidance Records” menu, display the frequency of display of the ECO guidance on a daily basis or during the split measurement period.
Page 112 EXPLANATION OF COMPONENTS OPERATION Operation on “Average Fuel Consumption Record” screen On “Average Fuel Consumption Record” screen, it is possible to perform the following operations with switches F1, F2, and F1: Clears the graph data. F2: Switches graphical displays of the average fuel consump- tion.
Page 113 OPERATION EXPLANATION OF COMPONENTS Deleting the Average Fuel Consumption Record When switch F1 (CLEAR) is pressed, the reconfirmation screen shown in the figure is displayed. When the switch F6 is pressed on the reconfirmation screen, graphs of data during last 12 hours and last 7 days are both deleted, and the screen returns to “Average Fuel Consumption Record”...
Page 114 EXPLANATION OF COMPONENTS OPERATION SET DISPLAY OF FUEL CONSUMPTION GAUGE It is possible to change the display of fuel consumption gauge (5) and the setting of Display/Non-display. Select “Average Fuel Consumption Display” (6) from “Con- figurations” screen, then press switch F6. On this screen, it is possible to perform the following oper- ations with switches F3 to F6.
Page 115 OPERATION EXPLANATION OF COMPONENTS REMARK When you select the split measurement, measurement stop switch F1 (“STOP”) is displayed on the “Operation Records” screen and the “ECO Guidance Records” screen. When you stop the measurement, select “Operation Records” (1) screen or “ECO Guidance Records” (2) screen on “Energy Saving Guidance”...
Page 116 EXPLANATION OF COMPONENTS OPERATION Select “ECO Gauge display” (8) from “Configurations” screen, then press switch F6. The “ECO Gauge Display” screen appears. “Traction”: Displays drawbar pull gauge (A) on the stand- ard screen. “Fuel Consump”: Displays ECO gauge (B) on the standard screen.
Page 117 OPERATION EXPLANATION OF COMPONENTS On this screen, it is possible to perform the following oper- ations with switches F3 to F6. F3: Decreases the target fuel consumption value by 1 ℓ/h. F4: Increases the target fuel consumption value by 1 ℓ/h. F5: Cancels the setting change and returns to Configura- tions screen.
Page 118 EXPLANATION OF COMPONENTS OPERATION Select “ECO Guidance Display at Key OFF” (13) from “Configurations” screen, then press switch F6. The setting screen for “ECO Guidance Display at Key OFF” appears. ON: Displays ECO Guidance (12) on the end screen. OFF: Does not display ECO Guidance (12) on the end screen.
Page 119 OPERATION EXPLANATION OF COMPONENTS If the fan reverse operation is performed while the aftertreat- ment devices regeneration display (A) displays that the regen- eration is in operation, the engine speed may not increase even if the fuel control dial is set to High idle (MAX) position, but this is not a failure.
Page 120 EXPLANATION OF COMPONENTS OPERATION 11. Since fan reverse rotation is set, start the engine. After the engine is started, the fan rotates in reverse, and the machine monitor screen displays as shown in the fig- ure. If the aftertreatment devices regeneration display (A) dis- plays that the regeneration is in operation while the fan is rotated in reverse, the engine speed may decrease to 1100 rpm, regardless of the position of the fuel control dial.
Page 121 OPERATION EXPLANATION OF COMPONENTS 12. After finishing the work, press switch F5 and stop the fan reverse rotation. 13. Set the fuel control dial to Low idle (MIN) position. 14. Turn the starting switch to OFF position to stop the engine. AUTO IDLE STOP TIMER SETTING The auto idle stop function stops the engine automatically when the engine is operated continuously at idle with the lock lever in LOCK position for a set time.
Page 122 EXPLANATION OF COMPONENTS OPERATION Select the set time on the “Auto Idle Stop Timer Setting” screen shown, and then press switch F6. On “Auto Idle Stop Timer Setting screen”, it is possible to perform the following operations with switches F3 to F6. F3: Moves to the next item (1 line below).
Page 123 OPERATION EXPLANATION OF COMPONENTS SCR INFORMATION Each item in “SCR Information” menu (d) is for displaying the information related to SCR and DEF. MAINTENANCE SCREEN SETTING Each item of setting menu (e) on “Maintenance” screen is used for displaying and setting the notification relevant to mainte- nance.
Page 124 • If you want to change the setting for the maintenance time or maintenance notice time (initial setting: 30 hours), consult your Komatsu distributor. Operations on “Maintenance Due Time Reset” screen On “Maintenance” screen, if switch F6 is kept pressed for 1.5 seconds or more, the screen changes to “Mainte- nance Due Time Reset”...
Page 125 Never drive the machine (in reverse) while watching only the camera screen. Be sure to visually check the safety around the machine. The guide lines indicate blade width lines and a line 5 m away from the rear of the machine. When changing the blade, ask your Komatsu distributor for adjustment of the camera screen. 3-69...
Page 126 EXPLANATION OF COMPONENTS OPERATION Select camera “Screen Adjustment (Camera)” on the “Monitor Setting” menu screen. Press switch F6. On “Screen Adjustment (Camera)” screen, the following items related to the camera screen can be set. • Camera image screen brightness adjustment •...
Page 127 OPERATION EXPLANATION OF COMPONENTS REMARK • If the light switch is at night mode ON, and the screen is adjusted, it is possible to adjust the brightness of the monitor screen (night mode). • If the light switch is at day mode ON, and the screen is adjusted, it is possible to adjust the brightness of the monitor screen (day mode).
Page 128 EXPLANATION OF COMPONENTS OPERATION Select “Clock Adjustment” (3) on “Monitor Setting” menu screen. Press switch F6. The screen changes to “Clock Adjustment” screen. The following 5 items can be changed. (a): “GPS Synchronization” (b): “Calendar” (c): “Time” (d): “12h/24h Mode” (e): “Daylight Saving Time”...
Page 129 OPERATION EXPLANATION OF COMPONENTS Select “Calendar” (b) on “Clock Adjustment” screen, then press switch F6. The “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display (A). If it is not necessary to change the year setting, press switch F6.
Page 130 EXPLANATION OF COMPONENTS OPERATION Select “Time” (c) on “Clock Adjustment” screen, then press switch F6. The “Time” screen is displayed. When the hour display (D) is highlighted in yellow, operate the switches as follows to change hour display (D). If it is not necessary to change the hour setting, press switch F6.
Page 131 OPERATION EXPLANATION OF COMPONENTS “12h/24h Mode” screen appears. F3: Moves to the next item (1 line below). Moves to the top line when it is on the bottom line. F4: Moves to the previous item (1 line above). Moves to the bottom line when it is on the top line.
Page 132 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID”...
Page 133 OPERATION EXPLANATION OF COMPONENTS When the starting switch is ON and “SKIP” is selected, “****” is displayed in the column of “Operator ID” on the “Monitor Set- ting” menu screen. Select “Operator ID” (5) on the “Monitor Setting” menu screen, then press switch F6 for 1 second. The “Operator ID Change”...
Page 134 EXPLANATION OF COMPONENTS OPERATION • When you press switch F6 after inputting the ID which is not registered to the “Operator ID Change” screen, a message is displayed below and the screen returns to the “Monitor Setting” menu screen. In this case, the identified ID is not changed. •...
Page 135 In this case, the identified ID is not changed. MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this User Message menu (g). When there is any message, the User Message (1) at the top of the standard screen lights up.
Page 136 EXPLANATION OF COMPONENTS OPERATION CHECK MESSAGE On the standard screen, press switch F6. When there is any message, message display (1) lights While message display (1) is lit, press switch F6, and the mail confirmation menu (e) directly opens. Select the mail confirmation menu (e), and you can read the received message.
Page 137: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES (1) Air conditioner switch (7) Engine shutdown secondary switch (2) Cigarette lighter (24 V) (8) Starting switch (3) Fuel control dial (9) Horn switch (4) Rear lamp switch (10) Room lamp switch (5) Headlamp switch (11) Wiper switch (6) Foot heater switch STARTING SWITCH...
Page 138 EXPLANATION OF COMPONENTS OPERATION FUEL CONTROL DIAL WARNING • When turning the fuel control dial to High idle (MAX) side while machine is stopped, check that the joystick (steering, directional and gear shift lever) is in NEUTRAL position. If the fuel control dial is turned to High idle (MAX) side while the joystick (steering, directional and gear shift lever) is in FORWARD or REVERSE position, the machine moves off suddenly and this may lead to serious per- sonal injury or death.
Page 139 OPERATION EXPLANATION OF COMPONENTS WIPER SWITCH The wiper switch operates the windshield wiper. The wiper switches are as follows. (A) LH: Left door (B) FF: Front window (C) RH: Right door (D) RR: Rear window (E) INT: Intermittent operation switch (for right and front doors) REMARK If the wiper blade is locked for some reason, the wiper stops automatically.
Page 140 EXPLANATION OF COMPONENTS OPERATION HORN SWITCH If you press the horn switch, the horn sounds. The horn switch is installed at the rear of the blade control lever on the right of the operator's seat. HEAD LAMP SWITCH The headlamp switch is used to light up the head lamp and monitor illumination.
Page 141 • Use the engine shutdown secondary switch only in an emergency. Immediately ask your Komatsu distributor for repair of the problem. • If this switch is set to the “STOP ENGINE” position by mistake while the machine is operating nor- mally, “Engine Shutdown Secondary SW In Operation”...
Page 142 EXPLANATION OF COMPONENTS OPERATION FOOT HEATER SWITCH Foot heater (a) is operated by foot heater switch. (A) LO position (B) Center position (C) HI position High The lamp inside the switch lights up by operating the switch. AIR CONDITIONER SWITCH Air conditioner switch is used to control the air conditioner.
Page 143: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS (1) Work equipment lock lever (4) Decelerator/brake pedal (2) Parking brake lever (5) Blade control lever (3) Joystick (steering, directional and gear shift lever) BLADE CONTROL LEVER The blade control lever is used for lifting, tilting and angling of the blade. Lifting operation (A) RAISE Blade rises.
Page 144 EXPLANATION OF COMPONENTS OPERATION Tilting operation (E) LEFT tilt Blade tilts leftward. (B) HOLD Blade is stopped and held in this position. (F) RIGHT tilt Blade tilts rightward. Machine Tilting amount ( mm) model Narrow blade Width blade High capacity blade D51EX –...
Page 145 OPERATION EXPLANATION OF COMPONENTS DECELERATION/BRAKE PEDAL WARNING • When passing over the top of a hill or when dumping soil from a cliff, the load on the machine will suddenly be reduced and the travel speed will increase. This situation is dangerous. Depress the decelerator/brake pedal to lower the travel speed.
Page 146 EXPLANATION OF COMPONENTS OPERATION REMARK • When setting the parking brake lever to LOCK position, (L) return the joystick (steering, directional and gear shift lever) to N (NEUTRAL) position. • When starting the engine, set the parking brake lever to LOCK position (L). When the parking brake lever is not in LOCK position (L), the limit switch is actuated, and the engine does not start.
Page 147 OPERATION EXPLANATION OF COMPONENTS Forward/reverse switching operation (A) FORWARD (N) NEUTRAL (B) REVERSE Move to the front to travel forward; move to the rear to travel in reverse. Steering operation (L) Turn LEFT (N) NEUTRAL (R) Turn RIGHT When the lever is tilted halfway in the direction you are turning while it is tilted in FORWARD or REVERSE, the machine turns.
Page 148: Other Equipment
EXPLANATION OF COMPONENTS OPERATION Even if gear is shifted down by automatic shifting, speed range display does not change. REMARK • When the gear is shifted, the current speed range is dis- played in the speed range display section of the machine monitor.
Page 149 OPERATION EXPLANATION OF COMPONENTS SASH GLASS INTERMEDIATE LOCK When working with the cab sash glass open, use this lock to prevent the glass from chattering. • When the lever is in FREE position (F), the glass can be opened or closed. •...
Page 150 EXPLANATION OF COMPONENTS OPERATION This is on the left side of the operator's seat. Always extinguish your cigarette before putting it in the ashtray, and be sure to close the lid. LUNCH BOX FIXING BELT This is the place for lunch box. Fix the lunch box with belt.
Page 151 OPERATION EXPLANATION OF COMPONENTS Power source outside cab 24 V power supply NOTICE • Do not use this as a power supply for 12 V equipment. This will cause failure of the equipment. • Do not install equipment which exceeds 120 W (24 V x 5 A).
Page 152 EXPLANATION OF COMPONENTS OPERATION Fuse capacities and circuit names Fuse box (A) Fuse ca- Name of circuit pacity 30 A Front lamp and rear lamp 10 A Horn and preheater 15 A Foot heater 30 A Air conditioner 10 A Machine controller 1 15 A Air suspension seat and winch 30 A Cab power supply 1 30 A...
Page 153 OPERATION EXPLANATION OF COMPONENTS Fuse box (C) Fuse ca- Name of circuit pacity 10 A Radio 20 A Additional working lamp 20 A Cigarette lighter and 12 V socket 10 A Radio and lamp 10 A Front windshield wiper and rear windshield wiper 10 A R.H. and L.H. door windshield wipers FUSIBLE LINK NOTICE When replacing the fusible link, be sure to turn the starting switch to OFF position and, after confirming...
Page 154 It can be installed at the rear part of the operator's seat. Mounting bracket (optional) is necessary for installation. For details of the parts necessary for installation, consult your Komatsu distributor. The directions are described on the nameplate affixed to the fire extinguisher. Just in case, carefully read and understand them beforehand.
Page 155 OPERATION EXPLANATION OF COMPONENTS It can be installed at the rear part of the operator's seat. For details of the parts necessary for installation, consult your Komatsu distributor. BATTERY DISCONNECT SWITCH CAUTION • Do not operate the battery disconnect switch while the engine is running.
Page 156 • After the starting switch has been turned off, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. • While DEF system devices are operating, the system operating lamp lights up to return DEF to the tank.
Page 157 OPERATION EXPLANATION OF COMPONENTS RADIATOR GRILLE Open and close the radiator grille as needed in check and maintenance. METHOD FOR OPENING AND CLOSING RADIATOR GRILLE WARNING • Before opening and closing the radiator grille, stop the engine and check that the fan is stopped. If you touch the rotating fan, it will cause serious personal injury or death.
Page 158 2000 hours. • If the engine is operated without KCCV filter element or if a filter element other than the Komatsu genuine element is used, the engine sucks oil and foreign ma- terial which can cause a failure. Always install Komat- su genuine KCCV filter element.
Page 159 Urea SCR systems. Alerts in Induce- ment of the Komatsu Urea SCR System progress step by step. It starts with visual indications on the machine monitor with audible sounds to engine power deration to avoid dangerous conditions.
Page 160 EXPLANATION OF COMPONENTS OPERATION Low-level requirement for regeneration • When caution lamp (2) comes on in yellow (action level (3): “L01”, screen (A) is displayed first. • The action level goes out after 2 seconds and the screen changes to standard screen (B). •...
Page 161 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR MANUAL STATIONARY REGENERATION When the manual stationary regeneration is required, check whether the caution lamp (1) is lit. During manual stationary regeneration, there are times when engine low idle speed increases automatically. Move the machine to a safe area and stop it with the en- gine running.
Page 162 EXPLANATION OF COMPONENTS OPERATION When manual stationary regeneration is not activated even af- ter you push the switch F6, return to the normal screen. Then push the switch F5, and follow the instructions shown on the screen. Manual stationary regeneration may continue for over 40 mi- nutes.
Page 163 OPERATION EXPLANATION OF COMPONENTS Even if regeneration is disabled, the aftertreatment device re- generation display (1) may come on under certain condition. In this case, it is impossible to disable regeneration. Procedures to stop the regeneration When aftertreatment device regeneration display (1) is lit on the standard screen, push F6 on the standard screen to open the “Aftertreatment Devices Regeneration”...
Page 164 EXPLANATION OF COMPONENTS OPERATION Push F6 on the normal screen, to open the “Aftertreatment Devices Regeneration” screen. If this screen does not show, push F1 and F2 to toggle to this screen. Select Yes to cancel regeneration disable and push F6. ABOUT THE OPERATION OF UREA SCR SYSTEM The Urea SCR System automatically starts operating as soon as the engine is started.
Page 165 OPERATION EXPLANATION OF COMPONENTS The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low level Inducement and Severe Inducement. The DEF level caution lamp (1) on the machine monitor will light up, audible alert will start, then Action level will be dis- played on the machine monitor, and engine power will be derat- ed in steps.
Page 166 EXPLANATION OF COMPONENTS OPERATION • Continuous Warning: The audible alert sounds in repetition of “three beeps and a pause”. 2 gradations of the DEF level gauge light up in the red range. DEF level caution lamp (1) lights up in red. No Action level is displayed.
Page 167 OPERATION EXPLANATION OF COMPONENTS Inducement status (4): “4 Engine power is under heavy de- ration.” Engine power can be restored temporarily from power derate. This engine power restoration works only when the Inducement status is “Severe Inducement”and relieves back temporarily to the power deration of the “Low level Inducement”.
Page 168 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen displays remaining time to the next Inducement status in the column (5), and information on the Urea SCR System condition (3), and the current status of In- ducement (4). • Warning: No audible alert. The DEF system caution lamp (1) lights up in yellow.
Page 169 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Low level Inducement”.
Page 170 “Severe Inducement”, the engine power will be further derated. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 171 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen message (5): “1 Please inspect and maintain SCR system.” Engine power is derated. Move the machine to the safe place and contact your Ko- matsu Distributor. If operation continues for 5 hours after “Warning” started without taking any actions instructed by the Action Level table, Inducement advances to “Continuous Warning”.
Page 172 “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In- ducement” and it becomes necessary to restore engine power, use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor. TEMPORARY RESTORATION FROM INDUCEMENT Temporary Restoration from Inducement is the one of the Inducement strategies allowed to be included in Urea SCR systems.
Page 173 OPERATION EXPLANATION OF COMPONENTS Press F6 to display the menu windows popping up in the bottom half of the “SCR Information”. The menu windows popping up in the bottom half of the “SCR Information” screen alternate every 15 seconds as shown in the graphics A and B.
Page 174 Inducement. If this occurs, utilize “Temporary Restoration from Inducement” and move to the machine to a safe place, and contact your Komatsu distributor. The maximum duration of power restoration is 30 minutes and 3 operations are allowed.
Page 175 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 176: Machine Operations And Controls
Clean DEF line and check it for leakage. Check around DEF tank for dirt, and clean the blue DEF filler cap and the area around. Check DEF tank, pump, injector, hoses, and joints for leakage. If any problem is found, ask your Komatsu distributor for re- pair.
Page 177 11. Check the seat belt and mounting hardware. Check the seat belt and mounting hardware for any abnormality. If any damage is found, ask your Komatsu distributor to replace it with new one. 12. Check and clean the camera.
Page 178 MACHINE OPERATIONS AND CONTROLS OPERATION Open the fuel tank inspection cover on the right side of the machine. The water separator is integrated with fuel prefilter (1) and located in the lower part. Check the water level and sediment through transparent cup (2).
Page 179 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 180 MACHINE OPERATIONS AND CONTROLS OPERATION • When the oil level is below L mark The oil is insufficient. Add hydraulic oil through oil filler port (F) on top of the hydraulic tank. REMARK The oil level changes depending on the oil tempera- ture.
Page 181 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. Check the oil level either before engine starts or at least 15 minutes after the engine stops.
Page 182 MACHINE OPERATIONS AND CONTROLS OPERATION Remove the cover (3). Pull out the hose (4). Loosen the drain plug (P) to drain the excessive oil. When draining the oil, put a container to catch the oil under hose (4). Check the oil level again. After the oil is adjusted to a proper level, insert the dipstick (G) fully into the dipstick pipe again.
Page 183 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 184 MACHINE OPERATIONS AND CONTROLS OPERATION Check the remaining level by the fuel gauge on the ma- chine monitor. • When the pointer is in green range (a) to (c) The fuel level is proper. • When the pointer is in red range (a) to (b) The fuel is insufficient.
Page 185 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the alarm buzzer sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and inspection. DEF injector and/or DEF pump may need to be replaced.
Page 186 MACHINE OPERATIONS AND CONTROLS OPERATION Open the DEF tank filler port cover (1). For opening and closing of the cover, see “METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT COVER”. Turn the DEF tank filler port cap (2) counterclockwise (O) and open it.
Page 187 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • It is recommended to use a nozzle having a diameter and a length specified by ISO 22241-4 and an auto stop function to add DEF. When the specified nozzle is used, the magnet installed inside the filler port of the tank cancels the wrong fluid addition prevention device, and you can add DEF.
Page 188 MACHINE OPERATIONS AND CONTROLS OPERATION Open the DEF tank filler port cover (1). For opening and closing of the cover, “METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT COVER”. Check the positions of (a) to (d) shown in the figure. Put the BIB container gently on it.
Page 189 OPERATION MACHINE OPERATIONS AND CONTROLS Insert the bellows hose of the BIB container into the filler port (2). If it is difficult to insert the bellows hose into filler port (2), make the end of the BIB container and (a) and (b) as ful- crum, and lift up the other end of BIB container to perform the work.
Page 190 If the lamps do not light up, a broken bulb or disconnected wire are the possible causes. Ask your Komatsu distributor for repairs. After finishing the check, turn the head lamp to OFF posi- tion (c) and turn the rear lamp to OFF position (e).
Page 191 2 sec- onds. If they do not light up, the machine monitor may be defective or may have an open circuit. Ask your Komatsu distributor for the inspection. METHOD FOR REMOVING DEPOSIT IN ENGINE COMPARTMENT Check that there is no deposit inside the engine compartment, particularly around the turbocharger, exhaust manifold, and aftertreatment devices.
Page 192 If the stroke is 60 mm or more, adjust it. Depress the decelerator/brake pedal fully. Check that the distance of stroke (A) at the center of the pedal is 50 to 60 mm. When it exceeds 60 mm or the brake force is insufficient, ask your Komatsu distributor for adjustment. 3-136...
Page 193 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR'S SEAT WARNING • When adjusting the position of the operator's seat, always set the work equipment lock lever and parking brake lever to LOCK positions to prevent any accidental contact with the control levers. •...
Page 194 MACHINE OPERATIONS AND CONTROLS OPERATION • To raise the front of the seat, apply your weight to the rear of the seat, while pulling up lever. • To lower the front of the seat, apply your weight to the front of the seat, while pulling up lever. Tilt adjustment: Up 5 °, down 5 °...
Page 195 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR HEATING SEAT Turn on the seat heater switch. (a): OFF position (b): ON position The backrest and seat surface are heated. When the seat heater switch is turned on, the heater in the seat operates. When the seat surface temperature exceeds approximately 20 °C, the heater is turned off automatically.
Page 196 MACHINE OPERATIONS AND CONTROLS OPERATION Pull up the reclining adjustment lever and set the seat back to a position which is comfortable for operation. Foremost reclining: Approx. 66 ° (Approx. 1.9 ° x 35 steps) Rearmost reclining: Approx. 72 ° (Approx. 1.9 ° x 38 steps) Sit with your back against the backrest when adjusting.
Page 197 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING WEIGHT AND HEIGHT OF SEAT Pull out the crank of knob (1) under the seat and turn it so that weight indicator (2) reads the green range. You can adjust the height by turning knob (1) in the green range. X: When crank is stored Y: When crank is pulled out (for adjusting weight) Adjust the weight according to the following procedure.
Page 198 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING LUMBER SUPPORT Turn the adjustment knob to the right or left, and give proper tension to the waist part. The back cushion tension is increased by turning the adjust- ment knob to the right. The tension of the back cushion can be adjusted to 5 steps.
Page 199 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION Pull up the fore-aft adjustment lever, and set the seat to the desired position. Fore-and-aft adjustment range: 210 mm (21 steps) After adjusting, release the lever. METHOD FOR RECLINING SEAT The reclining of the seat becomes large when the seat is moved forward, and it becomes smaller as the seat is moved backward.
Page 200 MACHINE OPERATIONS AND CONTROLS OPERATION Pull up the height adjustment lever fully, and then release it. The seat cushion is adjusted automatically. • The weight-based adjustment starts as soon as the height adjustment lever is pulled lightly. Pull it up fully until it clicks, and then release it.
Page 201 OPERATION MACHINE OPERATIONS AND CONTROLS Press the adjustment switch to give proper tension to the waist part. Press (+) side: Tension of backrest increases. Press (-) side: Tension of backrest decreases. Adjust the curve of backrest to your desired shape. METHOD FOR ADJUSTING DAMPER Turn the adjustment knob to adjust the hardness of damper to the desired level.
Page 202 MACHINE OPERATIONS AND CONTROLS OPERATION Loosen bolts (1) on the R.H. and L.H. of the operator's seat. (2 places each) Adjust the R.H. and L.H. armrests of the operator's seat to proper height. Tighten bolts (1) securely. The armrests are fixed. METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING •...
Page 203 OPERATION MACHINE OPERATIONS AND CONTROLS Pull the belt lightly to check that it is properly locked. If the tongue is not inserted in the buckle, the seat belt caution lamp is displayed at the top left of the machine monitor. METHOD FOR UNFASTENING SEAT BELT Press button (2) in buckle (1) and remove tongue (3) from buckle (1).
Page 204 MACHINE OPERATIONS AND CONTROLS OPERATION Check that parking brake lever (1) is in LOCK position (L). If parking brake lever (1) is not in LOCK position (L), the engine cannot be started. Check that joystick (steering, directional and gear shift lev- er) (2) is in NEUTRAL position (N).
Page 205 If a password is set, the input display screen will be indi- cated on the machine monitor. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the password. 10. Perform the following inspection on the machine monitor.
Page 206 MACHINE OPERATIONS AND CONTROLS OPERATION Check that the screen changes to the gear shift mode display screen in approximately 2 seconds, and then it changes to the standard screen. • Hydraulic oil temperature gauge (5) • Engine coolant temperature gauge (6) •...
Page 207: Method For Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING ENGINE METHOD FOR STARTING ENGINE IN NORMAL WEATHER WARNING • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious personal injury or death.
Page 208 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the key in starting switch (2) to START position (C). The engine starts. When the engine starts, release the starting switch key (2). The key will return automatically to ON position (B). REMARK • White smoke may be discharged for a short time immediately after the engine is started or during the after- treatment devices regeneration in cold season, but this is not a failure.
Page 209 OPERATION MACHINE OPERATIONS AND CONTROLS NOTICE • Do not turn the starting motor continuously for more than 60 seconds in any case. If the engine does not start, wait for approximately 2 minutes, then repeat the procedure from step 2. •...
Page 210 MACHINE OPERATIONS AND CONTROLS OPERATION Check if the preheating pilot lamp on the machine monitor (3) is lit. Leave this condition until the preheating pilot lamp goes out. The time that the preheating pilot lamp stays lit depends on the ambient temperature as shown in the table. Ambient temperature Lighting time (sec.) ( °C)
Page 211 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • Regardless of the ambient temperature, if the key in starting switch (2) is turned counterclockwise from OFF position, the preheating pilot lamp lights up and preheating starts. (Preheating continues while the starting switch (2) is held at the left.) For the preheating time, see the table in step 5.
Page 212: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 213 (2) indicates green range (A) to (C). • (A) to (B): Red range • (A) to (C): Green range • (C) to (D): White range Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. 3-157...
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ENGINE WARM-UP OPERATION IN COLD SEASON This machine is warmed up automatically by the automatic warm-up operation system. When the engine coolant temperature is 30 °C or less after the engine is started, the warm-up operation starts automatically. The automatic warm-up operation stops when the engine cool- ant temperature increases the specified temperature (30 °C) or after warm-up operation of 10 minutes even if the coolant tem-...
Page 215: Method For Stopping Engine
11. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. After warm-up operation, run he engine at medium speed and slowly drive forward and reverse so that the whole equipment becomes uniform temperature.
Page 216 MACHINE OPERATIONS AND CONTROLS OPERATION Turn the fuel control dial (1) to Low idle (MIN) position. Run the engine at low idle for approximately 5 minutes to cool down gradually. Turn the key in starting switch (2) to OFF position (A). The engine will stop.
Page 217: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE METHOD FOR MOVING MACHINE WARNING • Before moving the machine off, check that the area around the machine is safe, then sound the horn be- fore starting.
Page 218 MACHINE OPERATIONS AND CONTROLS OPERATION Set work equipment lock lever (6) to FREE position (F). Set blade control lever (7) to RAISE position (R) and raise the blade to 40 to 50 cm above the ground. Depress the decelerator/brake pedal. Set the joystick (steering, directional and gear shift lever) (4) to FORWARD position (F) or REVERSE position (R).
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS Make the machine move off by releasing decelerator/brake pedal (2) gradually. REMARK When moving off, the machine sometimes deviates a little, but this is due to actuation of straight-travel correction mechanism and it is not a failure. METHOD FOR STOPPING MACHINE WARNING •...
Page 220: Shift Gears
MACHINE OPERATIONS AND CONTROLS OPERATION To keep the machine stopped further, depress decelerator/ brake pedal (3) until depressing effort becomes large. SHIFT GEARS Speed range can be changed while traveling, it is not necessary to stop the machine for gear shifting. Select a desired speed range by depressing UP switch or DOWN switch of joystick (steering, directional and gear shift lever) (1).
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS QUICK SHIFT MODE • Press UP switch (U) of the joystick (steering, directional and gear shift lever) once, and speed range changes 1st → 2nd and 2nd → 3rd. • Press DOWN switch (D) of the joystick (steering, direction- al and gear shift lever) once, and speed range changes 3rd →...
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION • FORWARD/REVERSE (E) is displayed in the speed range display section. FORWARD/REVERSE (E) “F”: FORWARD “R”: REVERSE “N”: NEUTRAL “P”: Parking brake is being applied • Upper bar graph (G) lights up in accordance with set travel speed in forward.
Page 223: Method For Switching Between Forward And Reverse
OPERATION MACHINE OPERATIONS AND CONTROLS • Reverse travel speed can be set with reverse travel speed setting switch (A) and (B). • Each time switch (A) is pressed, the set travel speed in- creases. • Each time switch (B) is pressed, the set travel speed de- creases.
Page 224: Method For Steering Machine
Check that the backup alarm sounds when the joystick (steering, directional and gear shift lever) is set to RE- VERSE. If the alarm does not sound, ask your Komatsu distributor for repair. Release decelerator/brake pedal (1) and raise the engine speed.
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TURNING THE MACHINE WHILE TRAVELING FORWARD When gradually turning to the left, tilt the joystick (steering, di- rectional and gear shift lever) forward and tilt it to left (L) half- way. Any turning radius can be set until the operating effort of joy- stick (steering, directional and gear shift lever) becomes large.
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION On “Steering Mode” screen, press the switch F3 or F4 to move the yellow cursor to “Normal”, then press the switch F6. To make counter-rotation turn to the left, tilt the joystick (steering, directional and gear shift lever) forward and tilt it to left (L), and tilt it fully further from the point where the joystick operating effort becomes large.
Page 227: Recommended Working Modes For Works
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TURNING WHILE TRAVELING ON DOWNHILL METHOD FOR TURNING THE MACHINE GRADUALLY WHILE TRAVELING FOR- WARD When gradually turning to the left, tilt the joystick (steering, di- rectional and gear shift lever) forward and tilt it to left (L) half- way.
Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION Pedal mode Pedal mode can be changed with pedal mode selector switch (3). Pedal mode Features Depress the decelerator/brake pedal, and travel speed and engine speed lowers. Decelerator mode Use this mode for general operations. Depress the decelerator/brake pedal, and the travel speed lowers, but the engine speed does not lower.
Page 229: Precautions For Operation
OPERATION MACHINE OPERATIONS AND CONTROLS AA: Standard screen, MM: “Mode Select” screen (1) Gear shift mode selector switch (3) Pedal mode selector switch (2) Operating mode selector switch RECOMMENDED WORKING MODES Operating mode Type of operation Soil quality Operating conditions Normal soil Heavy-duty operations, high productivity desired ○...
Page 230: Precautions When Operating On Slope
MACHINE OPERATIONS AND CONTROLS OPERATION PERMISSIBLE WATER DEPTH When operating in water, always keep the bottom of carrier roll- ers (1) above the surface of the water. Also, be careful that the hydraulically driven cooling fan will not come in contact with water in order to prevent the breakage of the fan.
Page 231: Do Not Open Door While Operating Machine
OPERATION MACHINE OPERATIONS AND CONTROLS When working on slopes with an angle of more than 20 °, if the fuel level on the fuel gauge enters the red range, add fuel im- mediately. (A): Red range (B): Green range Pay attention to oil level When operating machine on a slope of 20 °...
Page 232 MACHINE OPERATIONS AND CONTROLS OPERATION DOZING WORK Cut soil and sand and move them forward. When cutting a slope surface, it is more efficient to always cut from top toward bottom. When dozing toward one side only, operate with angled blade. REMARK If the blade is hard to be raised during digging, adjustment of the blade edge angle will improve the condition.
Page 233: Method For Adjusting Work Equipment
OPERATION MACHINE OPERATIONS AND CONTROLS WORKS OF FELLING TREES AND REMOVING STUMPS NOTICE Do not perform stump removal or other hard work by angling tilting the blade. For trees with a diameter of 10 to 30 cm, raise the blade high and push a few times to fell the tree.
Page 234: Tips For Longer Undercarriage Life
OPERATION METHOD • Use a track shoe suitable for soil condition. For selection of the shoe, consult your Komatsu distributor. • Do not let the shoe slip during operation. If the shoe starts slipping, decrease the load to prevent slipping.
Page 235 Frequent inspection and prompt repair will reduce repair costs. The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per- form periodical inspection and contact the Komatsu distributor in your area when machine has approached re- pairable limits and reversing limits.
Page 236 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR MEASURE LINK PITCH Put a wooden block, etc. between the track shoe and sprocket to eliminate the sag of the track. Measure length (L) of 4 link pitches in a straight portion at least 2 links apart from master link (A).
Page 237: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR MEASURING TRACK ROLLER DIAMETER Measure the link tread (dimension C) as shown in the fig- ure. Stop the machine at a position where the link tread, at which dimension C was measured, is perfectly in contact with the roller tread.
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION Set joystick (steering, directional and gear shift lever) (2) to N (NEUTRAL) position. Position (A): FORWARD Position (B): REVERSE To keep the machine stopped further, depress decelerator/ brake pedal (1) until depressing effort becomes large. Set parking brake lever (3) to LOCK position (L).
Page 239: Method For Checking After Finishing Work
If oil or coolant leakage or any abnormality is detected, repair it. Check DEF tank, pump, injector, hose, and joint for leakage. If any abnormality is found, ask your Komatsu distributor for repair. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION Places locked with special key • Fuel filler port cap (9) REMARK If padlock (A) is to be used, it is recommended to use the type that has the cover to protect the key hole. METHOD FOR OPENING AND CLOSING CAP WITH LOCK PROCEDURE FOR OPENING CAP WITH LOCK Insert the key into the key slot.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS PROCEDURE FOR CLOSING CAP WITH LOCK Screw in the cap until it becomes tight, then insert the key into the key slot. Turn the starting switch key to “LOCK” position, then remove the key. METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP PROCEDURES FOR OPENING FUEL FILLER PORT CAP Raise lever (1) in the direction (a).
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION • Cover other than cab door opener Position (A): OPEN Position (B): CLOSE (LOCK) METHOD FOR LOCKING COVER WITH LOCK Close the cover and insert the key into the key slot. Turn the starting switch key to CLOSE position (B), then remove the key. METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT COVER CAUTION •...
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS Position (A): OPEN Position (B): CLOSE (LOCK) METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT CAP 3-187...
Page 244: Handle Air Conditioner
HANDLE AIR CONDITIONER OPERATION HANDLE AIR CONDITIONER Ventilation while cooling • When running the air conditioner for a long time, turn the lever to FRESH position once an hour to perform ventilation and cooling. • If you smoke when the air conditioner is on, the smoke may hurt your eyes. In such case, open the window and turn the lever to FRESH for a while for ventilation and driving smoke out.
Page 245: Method For Operating To Prevent Dust From Entering Into Cab
OPERATION HANDLE AIR CONDITIONER BLOWER CHANGEOVER SWITCH Blower selector switch is used to control the air flow at cooling and heating, and also used as a main switch. • It changes the air flow in 4 levels of 1 (low) → 2 → 3 → 4 (high).
Page 246: Method For Replacing Receiver
If the receiver is used with desiccating agent of which absorbing limit is over, the refrigerant circuit gets clogged and may cause the failure of compressor. Replace it every 2 years. REMARK The exchange interval may be shortened depending on the usage condition of receiver. Ask your Komatsu distributor for replacement of the receiver. 3-190...
Page 247: Handle Radio
OPERATION HANDLE RADIO HANDLE RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them. •...
Page 248 HANDLE RADIO OPERATION DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display. Each time you press this button, frequency, clock and band are shown on the display in this order. If 1.5 seconds passes while a band is shown, a frequency will be displayed. As long as AUX is selected, this button alternately switches the display between AUX and the clock.
Page 249: Method For Controlling Radio
OPERATION HANDLE RADIO Open cap (a). Connect a portable audio equipment by using an commer- cially available audio cable. Press the band/AUX selector button and select AUX. METHOD FOR CONTROLLING RADIO METHOD FOR ADJUSTING FREQUENCY Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency.
Page 250 HANDLE RADIO OPERATION METHOD FOR CALLING PRESET Press band/AUX selector button (1) and select FM or AM. Press one of 1 to 6 of preset button (2). The frequency registered in the preset number of the pressed button is called up and received. “Example”...
Page 251: Antenna
OPERATION HANDLE RADIO METHOD FOR ADJUSTING HIGH REGISTER RANGE (TREBLE) Press sound control button (1) to light up “TRE” on the dis- play. You can adjust the high register range (treble) of the sound. Press tuning/time adjustment button (2) to adjust the high register range (treble).
Page 252: Transportation
Operator's seat and control levers are made in one unit with the cab. If cab is removed, machine cannot be op- erated. If you have any trouble in transportation, consult your Komatsu distributor. METHOD FOR REMOVING WORK EQUIPMENT Overall width can be shortened by angling the blade fully. Re- ferring to the figure, decide whether the blade should be re- moved for transportation.
Page 253: Loading And Unloading With Trailer
OPERATION TRANSPORTATION LOADING AND UNLOADING WITH TRAILER WARNING • Since loading and unloading of the machine is dangerous, be extremely careful. • When loading or unloading the machine, lower the engine speed, set the speed range to the 1st, and operate slowly.
Page 254 TRANSPORTATION OPERATION Place the parking brake lever in FREE position (F). Set the speed range to 1st or less in variable mode. Set the travel direction toward the ramps and drive slowly. The center of gravity of the machine shifts suddenly at the joint between the ramps and the trailer, and the machine is unbalanced and becomes unstable.
Page 255 OPERATION TRANSPORTATION Front of the machine When no front work equipment is attached When front work equipment is attached (PAT specification) Rear of the machine When a drawbar is equipped 3-199...
Page 256 TRANSPORTATION OPERATION When a hitch is equipped When a ripper is equipped PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm and level ground. Park a trailer on a firm and level ground. Maintain a safe distance from the road shoulder Apply the brake of the trailer securely.
Page 257: Method For Lifting Machine
This lifting method applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. When lifting the machine, stop it on a level place, then lift it as follows.
Page 258 TRANSPORTATION OPERATION Select the lifting tool such as wire ropes and slings match- ing to the weight of the machine, and fit the wire ropes to the slinging position. (A) Mark indicating slinging position NOTICE • Use protectors, etc. so that the wire ropes will not be broken at sharp edges or narrow places.
Page 259: Cold Weather Operation
If DEF or the machine equipped with DEF system cannot be stored at the outside temperature is lower than –11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF, and keep it in the condition free from freezing.
Page 260: Precautions After Daily Work Completion
COLD WEATHER OPERATION OPERATION When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging rate as close as possible to 100%. Insulate it against cold temperature to ensure that the machine can be star- ted easily in the next morning.
Page 261 OPERATION COLD WEATHER OPERATION If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated freeze, ask your Komatsu distributor to inspect. 3-205...
Page 262: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, perform the following items before using it. •...
Page 263 If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement. Dispose of drained DEF according to the local regulations and rules.
Page 264: Troubles And Actions
If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic sys- tem, the brake works and the machine cannot move. To move the machine in this case, the oil pressure in the brake circuit must be heightened to the specified level with a special device. Contact your Komatsu dis- tributor.
Page 265: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS • If the machine gets stuck in the mud or a heavy thing needs to be towed, install a towing wire rope to the draw bar pin. Connect a wire rope to the part indicated with the arrow in the drawing.
Page 266 TROUBLES AND ACTIONS OPERATION METHOD FOR REMOVING AND INSTALLING BATTERY WARNING Stop the engine, and turn the starting switch and the battery disconnect switch keys to OFF positions when handling the battery. Prepare the wooden blocks. Open the hydraulic tank inspection cover (1). Turn the battery disconnect switch to OFF position (O).
Page 267 OPERATION TROUBLES AND ACTIONS Remove the wing bolts (5) (2 pieces) and remove the vinyl cover (6). Remove the bolts (7) (2 pieces) and remove the grease gun holder (8). Remove the bolts (9) (2 pieces) and remove the clip. Loosen the nuts of terminal (10) (2 places) and disconnect the cable from the battery.
Page 268 TROUBLES AND ACTIONS OPERATION 12. Remove the bolts (18) (2 pieces), and remove the bracket (19). 13. Loosen the nuts of terminal (20) (2 places) and disconnect the cable from the battery. Disconnect the ground cable (normally connected to the negative (-) terminal) first.
Page 269 OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, there is a danger that the battery may explode. Follow the instruction manual accompanying the battery charger, and observe the following. •...
Page 270 TROUBLES AND ACTIONS OPERATION NOTICE • The starting system for this machine uses 24 V. Accordingly, the normal machine must be equipped with a 24 V power supply. • The sizes of the jumper cables and clips should be suitable for the battery size. •...
Page 271: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 272 PHENOMENA AND ACTIONS FOR CHASSIS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 273 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 274 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Steam spurts out from top of radiator. Lowered coolant level, leakage of Check, add coolant, repair by refer- (pressure valve) coolant ring to CHECKS BEFORE START- ING. Dirt or scale accumulated in cooling Change coolant, flush inside of cool- system ing system by referring to WHEN RE-...
Page 275 (3) for the point of contact is displayed in the message column at the bottom of the screen. REMARK If no point of contact telephone number is registered, no tele- phone number is displayed. Ask your Komatsu distributor for the telephone number regis- tration if necessary. 3-219...
Page 277: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 278: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 279: Dusty Jobsites
MAINTENANCE PRECAUTIONS FOR MAINTENANCE DUSTY JOBSITES When working at dusty jobsites, observe the following. • Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged. • Replace the fuel filter more frequently.
Page 280: Fuel And Lubricants To Match The Ambient Temperature
PRECAUTIONS FOR MAINTENANCE MAINTENANCE Checks while the engine is running To perform inspection while the engine is running, one worker must always sit on the operator's seat and be ready to stop the engine at any time. All workers must maintain contact with the other workers. •...
Page 281: Outline Of Maintenance
OUTLINE OF MAINTENANCE OUTLINE OF MAINTENANCE • Komatsu recommends using Komatsu genuine parts for replacement parts, grease or oil. • 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 282 Always use ultra-low-sulfur diesel fuel. (≤10 ppm) The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel may contain 7 % or less of it. Do not use any additive agent which includes metallic constituent.
Page 283 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 284: Handle Electrical Components
• When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, consult your Komatsu distributor. • Do not open packages of spare filters until just before they are to be used.
Page 285: Handle Hydraulic Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working at the seashore, keep the electrical component clean to prevent corrosion.
Page 286: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 287 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Tightening torque Width Nominal - No. of across Target value Allowable range threads "a" flats "b" (mm) Nm kgm Nm kgm 9/16-18UNF 35 to 54 3.5 to 5.5 11/16-16UN 54 to 93 5.5 to 9.5 13/16-16UN 10.5...
Page 288: Maintenance Schedule
See “MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED”. • Ask your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE WHEN REQUIRED ............................4-15 METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER ..........
Page 289: Maintenance Interval When Diesel Fuel Mixed With Bio-Fuel Is Used
MAINTENANCE MAINTENANCE SCHEDULE TABLE METHOD FOR REPLACING DEF TANK BREATHER ELEMENT............4-59 CHECK AND REPLACE ALTERNATOR DRIVE BELT TENSION AND REPLACING ALTERNATOR BELT................................4-59 METHOD FOR CHECKING FOR LOOSE ROPS MOUNT BOLTS ............4-60 METHOD FOR CHECKING AND CLEANING FAN ................. 4-60 EVERY 2000 HOURS MAINTENANCE ......................
Page 290 MAINTENANCE SCHEDULE TABLE MAINTENANCE Fuel prefilter Replace. Replace. Replace. Replace. Replace. cartridge Fuel main fil- Replace. Replace. Replace. Replace. ter cartridge 4-14...
Page 291: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING • If inspection, cleaning, or maintenance is performed while the engine is running, dust enters into the engine and damages it. Be sure to stop the engine before performing these works. •...
Page 292 MAINTENANCE PROCEDURE MAINTENANCE • When the inside yellow piston of dust indicator (1) laps over the peripheral red zone (A) METHOD FOR CLEANING AND REPLACING OUTER ELEMENT Open the engine side cover on the left side of the machine. Remove the clips (2) (3 places) and remove the cover (3). NOTICE •...
Page 293 MAINTENANCE MAINTENANCE PROCEDURE Blow dry compressed air (0.2 MPa {2.1 kg/cm } or less) from the inside of the outer element along the pleats. Blow dry compressed air from the outside of the outer ele- ment along the pleats. Blow dry compressed air again from the inside of the outer element.
Page 294 MAINTENANCE PROCEDURE MAINTENANCE 14. Push the button of dust indicator (1). The yellow piston returns. REMARK • Immediately after a new element has been installed, the yellow piston of the dust indicator may go to the position in the range of 3.7 to 5.0 kPa {0.04 to 0.05 kg/cm }, but this does not indicate any abnormal- ity.
Page 295 MAINTENANCE MAINTENANCE PROCEDURE NOTICE • If the outer element and cover are installed while the inner element is not installed properly, the outer element may be damaged. • Do not clean and reuse the inner element. When replacing the outer element, replace the inner element with new one at the same time.
Page 296: Method For Cleaning Inside Of Cooling System
NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 297 MAINTENANCE MAINTENANCE PROCEDURE To close the heater valve, set the temperature setting of the air conditioner to the maximum cooling. Place the machine on a level place. Stop the engine. Turn the radiator cap (1) slowly until it hits the stopper and release the pressure.
Page 298 MAINTENANCE PROCEDURE MAINTENANCE Pull out the drain hose (4). Remove the cover (5) under the front cover. Place a container to catch the coolant under the drain hose (4). 10. Open the drain valve (P) to drain the coolant. REMARK Keep air bleeding valve (6) open while adding the coolant or water to the cooling system.
Page 299: Method For Cleaning Inside Machine
MAINTENANCE MAINTENANCE PROCEDURE 22. Add Non-Amine Engine Coolant (AF-NAC) to the middle between FULL and LOW. 23. Stop the engine. 24. Tighten the radiator cap (1). 25. Check the coolant level in reservoir tank (7). If necessary, add Non-Amine Engine Coolant (AF-NAC). 26.
Page 300: Method For Checking And Cleaning Radiator Front
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING AND CLEANING RADIATOR FRONT WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the com- pressed air, high-pressure water, or steam, there is a danger of personal injury. Always wear protective equipment such as protective eyeglasses and dust mask.
Page 301 METHOD FOR DECREASING TRACK TENSION WARNING It is extremely dangerous to release the grease by any method other than the following procedure. If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs. NOTICE • The safety indicator is stuck to the back of cover (3). Take care not to damage the safety indicator.
Page 302: Method For Checking Looseness And Tightening Track Shoe Bolts
MAINTENANCE PROCEDURE MAINTENANCE Remove cover (3). Loosen plug (1) gradually to release the grease. When loosening plug (1), turn it a maximum of 1 turn. If the grease does not come out smoothly, move the ma- chine forward and backward a short distance. Tighten plug (1).
Page 303: Method For Checking Idler Oil Level
When oil oozes out through thread portion You do not need to add oil. • When no oil oozes out through thread portion The oil is insufficient. Ask your Komatsu distributor for adding. After checking, tighten plug (1). METHOD FOR ADJUSTING IDLER CLEARANCE Since the idlers are forced to move forward and backward by an external force, guide plates will be worn out.
Page 304: Method For Inverting And Replacing Cutting Edge And End Bit
MAINTENANCE PROCEDURE MAINTENANCE Loosen the bolts (3) (4 pieces). Tightening torque: 245 to 309 Nm {25 to 31.5 kgm} Remove some shims and adjust the clearance on each side to 0.5 mm to 1 mm. Thickness of 1 shim is 1 mm. METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY Measure the clearance (B) to know the adjustment amount, subtract 2 mm {0.08 in} ...
Page 305: Clean And Check Radiator Fins And Oil Cooler Fins
MAINTENANCE MAINTENANCE PROCEDURE Wear standards Item Criteria ( mm) Standard Measuring point Repair limit dimension Height of end bit Height of cutting edge REMARK • If both sides of the cutting edge are worn out, replace with new ones. • If the wear extends to the mounting surface, repair the mounting surface before installing.
Page 306 MAINTENANCE PROCEDURE MAINTENANCE Set the parking brake lever (2) and work equipment lock lever (3) to LOCK positions (L). Remove the mounting bolts (8 pieces), and remove the covers (4) and (5). Open the engine side cover (6). Remove the front cover (7) and engine side covers (8) and (9).
Page 307 MAINTENANCE MAINTENANCE PROCEDURE REMARK Even if Fan Reverse Mode is set while the engine is run- ning, the fan rotation direction is not reversed. The screen in the figure is displayed to inform the operator that the direction of rotation of the fan has not been changed.
Page 308: Method For Cleaning Hydraulic Tank Breather
MAINTENANCE PROCEDURE MAINTENANCE Pull the radiator grille backward and raise it upward. Open the radiator grille to the fully opened position, check that it is locked, and then release your hand. Remove mud, dirt, leaves, etc. in the radiator fins. Blow off the heavy clogging with the compressed air.
Page 309: Method For Replacing Door Damper
MAINTENANCE MAINTENANCE PROCEDURE Remove nut (2) of breather assembly (1) on the top of the fuel tank. Use a tool when the nuts are so tight to remove. Remove cover (3). Remove dirt sticking to breather element (4). Clean in clean diesel fuel or flushing oil. Install cover (3) and nut (2).
Page 310: Method For Checking Door Latch
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING DOOR LATCH Keep the door open. Check if the grease in the latch dried out. If the amount of grease is low or there is no more grease, coat the inside of the latch with grease from portion (1). REMARK If there is no more grease inside the latch, the movement of the door will become poor because of dust inside the latch, and the handle may become heavy when you open the door.
Page 311: Method For Checking Wiper Blade
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING WIPER BLADE (1) Front wiper (4) Wiper arm (2) Rear wiper (5) Wiper blade (3) Door wiper Check each wiper visually, and replace the wiper blade in the following cases. • When wiping is uneven •...
Page 312: Method For Checking And Maintenance Air Conditioner
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING REAR WIPER The rear wiper is hooked at portion (A). Move the blade in the direction of the arrow. The blade comes off. Install the new blade and hook it securely. METHOD FOR REPLACING DOOR WIPER The front wiper is hooked at portion (A).
Page 313 MAINTENANCE MAINTENANCE PROCEDURE Remove the bolts (4) (2 pieces). Remove the bolts (5) (2 pieces) and remove the cover (6). Press the middle point between the compressor pulley (7) and idler pulley (8) with your finger (approximately 98 Nm {10 kgm }). If deflection (A) is 11.5 to 14.5 mm, the belt tension is nor- mal.
Page 314: Method For Bleeding Air From Hydraulic Circuit
Ask your Komatsu distributor for replacement of the belt. When it has been replaced with a new part, there will be initial elongation. After 2 or 3 days of operation, adjust it again.
Page 315 MAINTENANCE MAINTENANCE PROCEDURE NOTICE Abnormal heat will be generated if the pump is operated without filling the pump case with hydraul- ic oil. It may cause a premature damage to the pump. Be sure to bleed the air. Remove the cap of oil filler port (F) at the top of the hydraulic tank.
Page 316: Method For Releasing Pressure In Hydraulic Circuit
METHOD FOR CHECKING ELECTRICAL INTAKE AIR HEATER Check before starting in the cold weather (once a year). Ask your Komatsu distributor for check of the electrical intake air heater. METHOD FOR ADJUSTING SHIMS AT CENTER BALL WARNING Place the work equipment lock lever at LOCK position except when operating the blade for adjustment.
Page 317: Method For Adjusting Shims At Pitch Ball
MAINTENANCE MAINTENANCE PROCEDURE • Standard shim thickness: 6 to 8 mm Remove the bolt (1) and loosen the bolts (2) (5 pieces). Remove all the shims (3) and tighten the bolts (1) and (2) lightly so that the dimension of clearance (A) becomes even at whole circumference.
Page 318: Checks Before Starting
MAINTENANCE PROCEDURE MAINTENANCE Remove the bolt (1) and loosen the bolt (2). Remove all the shims (3) and tighten the bolts (1) and (2) lightly so that the dimension of clearance (A) becomes even at whole circumference. Measure the clearance (A) and set the shim thickness so that it is between (A + 0.2) and (A + 1.2) mm.
Page 319: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE When lubricating the lift cylinder bottom pin (1) and U-frame mounting pin (3), lower the blade to raise the idler 1 to 2 cm from the ground, then stop the engine. By using a grease pump, pump in grease through the grease fitting. After greasing, wipe off any old grease that is pushed out.
Page 320: Method For Lubricating Equalizer Bar Side Pin
MAINTENANCE PROCEDURE MAINTENANCE (1) Angle cylinder head pin (1 place each of right and left) (2) Tilt cylinder bottom pin (1 place) (3) Tilt cylinder head pin (1 place) METHOD FOR LUBRICATING EQUALIZER BAR SIDE PIN (1 place each on right and left sides) Remove all soil and sand from the top of the track frame and top of the cover.
Page 321: Method For Checking Battery Electrolyte Level
MAINTENANCE MAINTENANCE PROCEDURE Stop the machine so that the TOP mark comes on the top while a line between TOP mark and plug (P) becomes per- pendicular to the ground surface. Remove plug (F) by using a handle, and check the oil lev- •...
Page 322 If purified water is added to above U.L. line, use a syringe to lower the level to U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, con- sult your Komatsu distributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO...
Page 323: Method For Checking Brake Performance
If it is possible to use an indicator to check the electrolyte level, follow the instructions given. METHOD FOR CHECKING BRAKE PERFORMANCE WARNING If the machine moves off during the following operation, ask your Komatsu distributor for repairs imme- diately. Before starting the engine, check the safety around the machine, and then perform the following operation.
Page 324: Every 500 Hours Maintenance
When the machine can move or the warning screen is displayed on the machine monitor. Immediately ask your Komatsu distributor for repair. EVERY 500 HOURS MAINTENANCE Maintenance for every 50 and 250 hours should be performed at the same time.
Page 325 Tighten the drain plug (P). Check the drained oil. If there are excessive metal particles or foreign material, contact your Komatsu distributor. Install the cover (1). Remove the mounting bolts (6 pieces) from engine side cover (3) on the right side of the machine, and remove the engine side cover (3).
Page 326: Method For Replacing Fuel Prefilter Cartridge
MAINTENANCE PROCEDURE MAINTENANCE 13. After replacing the filter cartridge, open the engine side covers (5) and (6) on the left side of the machine. 14. Add oil through the oil filler port (F) until the oil level is be- tween H and L marks on dipstick (G). 15.
Page 327 The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 328 MAINTENANCE PROCEDURE MAINTENANCE 11. Fill the new filter cartridge with clean fuel, thinly apply oil to the packing surface, then install it to the filter head. NOTICE • When filling the filter cartridge with fuel, do not re- move the cap (B) at center. Always fill with fuel from the small holes (A) (8 places) on the dirty side.
Page 329: Method For Replacing Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE 16. Turn the starting switch key to START position (C) and start the engine. 17. Check the filter seal surface and the mounting face of the transparent cup for fuel leakage. If there is any leakage of fuel, check the tightening condi- tion of the filter cartridge.
Page 330: Every 1000 Hours Maintenance
ALTERNATOR CAUTION If there are traces of short-circuiting on the electric wiring, immediately ask your Komatsu distributor to locate the cause of it and to perform the repair. Remove the engine side cover (1) on the right side of the machine.
Page 331: Method For Replacing Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 332 MAINTENANCE PROCEDURE MAINTENANCE Open the fuel tank inspection cover on the right side of the machine. Turn the fuel supply valve (1) to CLOSE position (C). Open the engine side cover (2) on the left side of the ma- chine. Place a container under filter cartridge (3) to catch the fuel.
Page 333 MAINTENANCE MAINTENANCE PROCEDURE Turn the fuel supply valve (1) to OPEN position (O). 10. Bleed the air. Fill up the fuel tank with fuel (to the level where the float is at the highest position). Loosen the knob of feed pump (4), pull it out, then pump it in and out until the movement becomes heavy.
Page 334: Method For Replacing Fuel Tank Breather Element
METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT Remove nut (2) of breather assembly (1) on the top of the hydraulic tank.
Page 335: Method For Replacing Def Tank Breather Element
If the machine is operated without the DEF tank breather element attached, or with the element oth- er than Komatsu genuine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without the DEF tank breather element attached, nor use the element other than Komatsu genuine parts.
Page 336: Method For Checking For Loose Rops Mount Bolts
MAINTENANCE PROCEDURE MAINTENANCE Check the alternator drive belt. If alternator drive belt shows the following conditions, it must be replaced. Ask your Komatsu distributor to replace it. • When vertical flaw (2) that crosses horizontal flaw (1) is found. •...
Page 337: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Pull the radiator grille backward and raise it upward. Open the radiator grille to the fully opened position, check that it is locked, and then release your hand. Remove the bolts (2) (4 pieces) and remove the net (3). Wipe off the soil and sand, snow, ice and such which are stuck to the fan (4).
Page 338: Method For Changing Oil In Hydraulic Tank, Replacing Hydraulic Oil Filter Cartridge, Replacing Hst Oil Filter Cartridge, And Cleaning Hydraulic Tank Strainer
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHANGING OIL IN HYDRAULIC TANK, REPLACING HYDRAULIC OIL FILTER CARTRIDGE, REPLACING HST OIL FILTER CARTRIDGE, AND CLEANING HYDRAULIC TANK STRAINER WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 339 MAINTENANCE MAINTENANCE PROCEDURE Install the drain hose (2), which has been removed, to the drain port (3), and pass it through the hole of the bottom plate. Place an oil container to catch the oil under the drain hose (2). Loosen the drain valve (4) and drain the oil.
Page 340 27. After the packing surface touches the sealing surface of the filter head, tighten the filter cartridge approximately 2/3 of a turn. Komatsu recommends using Komatsu genuine cartridge. 28. Open the fuel tank inspection cover on the right side of the machine.
Page 341: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tor (For Control Circuit)
• Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 342 MAINTENANCE PROCEDURE MAINTENANCE Set the parking brake lever to LOCK position (L). Raise the work equipment (blade) to the upper limit. NOTICE Perform the following procedure (for lowering the blade to the ground) within 15 seconds after stopping the engine. When the engine is stopped, the pressure inside the accumulator gradually goes down, so this inspec- tion can be performed only immediately after the engine is stopped.
Page 343: Method For Checking Alternator
Check that the work equipment goes down to the ground under its own weight. In the following cases, the gas charge pressure of the accumulator has gone down. Contact your Komatsu dis- tributor. • Work equipment does not go down •...
Page 344 MAINTENANCE NOTICE • Komatsu recommends using Komatsu genuine parts for replacement parts. • If the engine is operated without the filter element, the turbocharger and aftercooler become dirty and their performance will lower and that can cause engine problems such as overrun caused by suction of oil.
Page 345 MAINTENANCE MAINTENANCE PROCEDURE Loosen the ring (4) of KCCV ventilator (2) by using the special wrench. After the ring (4) comes off, remove the case (5) from body (3), and remove the element (6). There may be oil accumulated or sticking in the case and element.
Page 346: Method For Replacing Def Filter
MAINTENANCE PROCEDURE MAINTENANCE Align the position of ◇ mark (9) on the case with that of ◇ mark (12) of the filter body label, then install the case to the filter body. The element can be installed only when its claw (13) and claw (14) of the case are correctly inserted in the groove (15) of the body.
Page 347 Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without the DEF filter attached, or with the filter other than Komatsu gen- uine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine.
Page 348 MAINTENANCE PROCEDURE MAINTENANCE Turn the cap (4) of filter removal tool (3) and remove it. Check the installation of spacer (5). Insert the filter removal tool (3) into the bottom of the DEF pump and thrust in by hand. Check that the filter removal tool (3) is fully inserted to the end.
Page 349: Every 4000 Hours Maintenance
Brake system Brake oil pressure hose Torque converter, transmission system Transmission circuit hose (including HST) (including HST) Ask your Komatsu distributor for re- Work equipment hy- Work equipment pump delivery hose placement. draulic system Work equipment pump LS hose Hose for hydraulic drive fan...
Page 350: Method For Checking Starting Motor
• Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. NOTICE If the nitrogen gas charge pressure in accumulator is low and operations are continued, it becomes im- possible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 351: Every 4500 Hours Maintenance
Check the fuel spray prevention caps visually or with a finger to see if any of them has slipped off, or the rubber portion is hardened. If there is any loose bolt or hardened rubber, ask your Komatsu distributor for replacement. EVERY 4500 HOURS MAINTENANCE Maintenance for every 50, 250 and 500 hours should be performed at the same time.
Page 352: Every 8000 Hours Maintenance
Maintenance for every 50, 250, 500, 1000 and 4500 hours service should be performed at the same time. METHOD FOR REPLACING DEF HOSE Ask your Komatsu distributor for replacement of the DEF hose. END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. 4-76...
Page 353: Specifications
SPECIFICATIONS...
Page 354: Specifications: D51Ex-24
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS: D51EX-24 With power angle power tilt dozer, ROPS cab Item Unit D51EX-24 13620 Machine weight kg [13680] Komatsu SAA6D107E-3 diesel Engine model engine SAE J1995 (gross) 99.2 / 2200 kW / Rated horsepower ISO 14396 99.2 / 2200 min...
Page 355 SPECIFICATIONS SPECIFICATIONS Item Unit D51PX-24 Komatsu SAA4D107E-3 diesel Engine model engine SAE J1995 (gross) 99.2 / 2200 kW / Rated horsepower ISO 14396 99.2 / 2200 min ISO 9249 / SAE J1349 (net) 97.6 / 2200 4800 Overall length mm...
Page 357: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 358: General Precautions
GENERAL PRECAUTIONS PRECAUTIONS FOR SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distrib- utor first.
Page 359: Handle Hydraulic Ripper
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER HANDLE HYDRAULIC RIPPER This ripper is applicable for D51EX. GENERAL VIEW (1) Ripper cylinder (4) Shank (2) Link (5) Point (3) Beam (6) Support EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER WARNING When performing inspection or maintenance of the machine, or when parking the machine, lower the ripper to the ground and set the work equipment lock lever to LOCK position.
Page 360 HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS The ripper control lever is used for operating the ripper. (a) RAISE: Ripper goes up (b) HOLD: Ripper is stopped and held in this position. (c) LOWER: Ripper goes down REMARK If the work equipment lock lever is set to LOCK position (L), the operation of the ripper is locked.
Page 361 ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER METHOD FOR OPENING RADIATOR GRILLE Remove the bolts (1) (4 pieces) on the lower part of the ra- diator grille, and remove the cover (2). Pull the radiator grille backward and raise it upward. Open the radiator grille to the fully opened position, check that it is locked, and then release your hand.
Page 362: Machine Operations And Controls
HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS MACHINE OPERATIONS AND CONTROLS CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE METHOD FOR WALK-AROUND CHECK Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the rivets.
Page 363: Troubles And Actions
OTHER TROUBLE • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy Lack of rising and pushing force...
Page 364: Check And Maintenance
Make the ripper point touch the ground. Stop the engine. Check oil level in hydraulic tank. For details, see OPERATION, “METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL”. SPECIFICATIONS: D51EX-24 Power angle power tilt dozer (Machine with ripper)
Page 365 ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER Item Unit D51EX-24 Machine weight kg 14570 (excluding the weight of opera- tor) Ripper unit weight kg A Overall length mm 5850 Number of shanks...
Page 367: Replacement Parts
REPLACEMENT PARTS...
Page 368: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 369: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 370: Recommended Fuel, Coolant, And Lubricant
Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu construction equipment and components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recom- mend any commercially available lubricant additive. •...
Page 371 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT The symbols used in the lubrication chart are explained in the following table.
Page 372: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
Replace HST oil filter Replace DEF tank breather element Replace DEF filter METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Ambient temperature, de- Recommended Komatsu grees Celsius( °C) Reservoir Fluid type Fluids Engine oil for KDPF used in...
Page 373: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems in the cooling system, including the engine.
Page 375: Index
INDEX INDEX Symbols Battery - Check electrolyte level impossible from side................4-46 12H24H display mode - Switch......3-74 Battery - Handle............ 2-29 1st travel speed setting......... 3-42 Battery - Remove / Install........3-210 2nd travel speed setting........3-43 Battery disconnect switch........3-99 3rd travel speed setting.........3-44 Battery electrolyte - Check level......
Page 376 INDEX Coolant..............3-203 Door hinge - Lubricate.......... 4-33 Coolant - Check level / Add........ 3-124 Door latch - Check..........4-34 Coolant and water for dilution......... 4-6 Door lock striker - Check........4-34 Cooling system - Clean inside......4-20 Door open lock............3-92 Counter-rotation turn - Operate......3-169 Door wiper - Replace..........
Page 377 INDEX Equalizer bar center pin - Lubricate...... 4-43 Fuel, coolant and lubricants according to ambient Equalizer bar side pin - Lubricate......4-44 temperature - Use..........7-6 Every 1000 hours maintenance......4-54 Function switches..........3-39 Every 2000 hours maintenance......4-61 Function switches and guidance icons....3-36 Every 250 hours maintenance......
Page 378 KCCV filter element - Replace......4-67 Machine monitor - Basic operation when stopping en- Keep machine clean..........2-9 gine in normal situation........3-7 Komatsu Closed Crankcase Ventilation (KCCV) 3-102 Machine monitor - Check........3-134 Komatsu genuine lubricants........4-2 Machine monitor - Operate when operator identifica- Komatsu genuine replacement parts......
Page 379 Precautions related to attachments and options...2-14 Pedal mode selector switch........3-39 Precautions related to protective structure... 2-14 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Precautions to prevent fire........2-10 Periodic replacement of defined life parts.....2-33 Precautions when installing hydraulic hoses..4-3 Phenomena and actions for chassis....
Page 380 Radiator grille - Close........3-101,6-5 Sound control button...........3-192 Radiator grille - Open........3-101,6-5 Specifications............5-2 Radiator grille - Open / Close....... 3-101,6-4 Specifications - D51EX-24........5-2,6-8 Radio - Control............3-193 Specifications - D51PX-24........5-2 Radio - Handle............ 3-191 Speed range display..........3-31 Read this manual............ 1-2 Stability..............
Page 381 INDEX Switches..............3-81 Wiper blade - Check..........4-35 System caution lamp..........3-18 Wiper blade - Replace.......... 4-35 System operating lamp........3-100 Wiper switch............3-83 Work equipment - Adjust......3-177,6-6 Work equipment - Remove......... 3-196 Work equipment lock lever........3-90 Temperature control switch......... 3-189 Work equipment lock pilot lamp......3-28 Temporary Restoration from Inducement....3-116 Work equipment system caution lamp....

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