Page 1 This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it. NOTICE Komatsu has Operation & Maintenance Manuals written in 2004 some other languages. If a foreign language manual is All Right Reserved necessary, contact your local distributor for availability.
Page 2 FOREWORD...
Page 3 Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically. In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
Page 4 FOREWORD FOREWORD...
Page 5 FOREWORD FOREWORD...
Page 6: Foreword
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa- tions.
Page 7 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 8: Introduction
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: q Dozing q Smoothing q Cutting into hard or frozen ground or ditching q Felling trees, removing stumps See the section “WORK POSSIBLE USING BULLDOZER (3-110)“ for further details.
Page 9: Necessary Information
FOREWORD NECESSARY INFORMATION NECESSARY INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is at the front bottom right of the operator's seat. The design of the nameplate differs according to the territory.
Page 10: Emission Control Information Label
FOREWORD NECESSARY INFORMATION EMISSION CONTROL INFORMATION LABEL This is at the top on the side face of the engine on the left side of the machine. POSITION OF SERVICE METER The service meter is provided at the lower part of the monitor panel.
Page 11: Table Of Contents
CONTENTS CONTENTS FOREWORD FOREWORD................................. 1-2 SAFETY INFORMATION............................1-5 INTRODUCTION..............................1-7 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE ............... 1-7 NECESSARY INFORMATION ..........................1-8 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........1-8 ENGINE SERIAL NO. PLATE........................1-8 EMISSION CONTROL INFORMATION LABEL ..................1-9 POSITION OF SERVICE METER ......................
Page 12: Contents
CONTENTS CHECK MONITOR SYSTEM ......................3-7 EMERGENCY CAUTION ITEMS ...................... 3-8 CAUTION ITEMS..........................3-10 METER GROUP ..........................3-12 LAMPS............................. 3-17 SWITCHES............................3-19 METHOD OF USING MAINTENANCE MODE................3-24 SWITCHES ............................... 3-33 CONTROL LEVERS AND PEDALS ......................3-37 CIRCUIT BREAKER ..........................3-44 FUSE ................................
Page 13 CONTENTS ADJUSTMENT..........................3-82 OPERATION AND CHECK BEFORE STARTING ENGINE............3-87 STARTING ENGINE ..........................3-89 NORMAL STARTING ........................3-89 STARTING IN COLD WEATHER ....................3-91 OPERATIONS AND CHECKS AFTER STARTING ENGINE ..............3-94 BREAKING IN THE NEW MACHINE ....................3-94 WARMING UP OPERATIONS ......................3-94 STARTING IN COLD WEATHER ....................
Page 14 OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ..........4-5 OIL ..............................4-5 FUEL..............................4-5 COOLANT ............................4-6 GREASE............................4-6 CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ..............4-6 STORING OIL AND FUEL......................... 4-7 FILTERS ............................4-7 RELATING TO ELECTRIC SYSTEM ......................4-8 1-13...
Page 15 CONTENTS WEAR PARTS LIST ............................. 4-9 WEAR PARTS LIST............................ 4-9 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..... 4-10 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ............4-10 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..............4-14 TORQUE LIST ............................4-14 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................
Page 16 CONTENTS EVERY 50 HOURS SERVICE ........................4-44 DRAIN WATER, SEDIMENT FROM FUEL TANK................4-44 LUBRICATING..........................4-44 EVERY 250 HOURS SERVICE ........................ 4-45 LUBRICATING..........................4-45 GREASE EQUALIZER BAR SIDE PIN.................... 4-47 GREASE EQUALIZER BAR CENTER PIN ..................4-47 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ..............4-48 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..............
Page 17 CONTENTS PRECAUTIONS RELATED TO SAFETY ....................6-2 HANDLING HYDRAULIC RIPPER........................6-3 GENERAL VIEW............................6-3 EXPLANATION OF COMPONENTS ......................6-4 OPERATION............................... 6-5 CHECK BEFORE STARTING ENGINE, ADJUST................6-5 PRECAUTIONS WHEN OPERATING....................6-5 ADJUSTING POSTURE OF WORK EQUIPMENT................6-5 TROUBLESHOOTING ..........................6-7 OTHER TROUBLE ..........................
Page 18: Safety
SAFETY...
Page 19 SAFETY SAFETY SAFETY SAFETY LABELS..............................2-42 POSITIONS OF SAFETY PICTOGRAMS ....................2-42 SAFETY LABELS............................2-52 GENERAL PRECAUTIONS Safety rules ..............................2-92 If abnormalities are found..........................2-92 Clothing and personal protective items ......................2-92 Fire extinguisher and first aid kit ........................2-92 Safety features ............................
Page 20 SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE ......................2-272 Warning tag..............................2-272 Keep work place clean and tidy ......................... 2-272 Appoint leader when working with others ....................2-272 Stop engine before carrying out inspection and maintenance ..............2-272 Two workers for maintenance when engine is running................2-282 Proper tools..............................
Page 21: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
Page 22: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating or maintaining machine (09651-03001) (2) Caution before moving in reverse (09802-13000) (3) Caution for leaving operator's seat (09654-33001)
Page 23 SAFETY SAFETY LABELS (4) Caution for high-temperature cooling water (09668-03001) (5) Caution for high-temperature oil (09653-03001) (6) Caution for accumulator (09659-53000) (7) Caution for adjusting track tension (09657-03003) The safety label is attached to the rear side of the track adjust- ment window cover.
Page 24 SAFETY SAFETY LABELS (8) Caution for battery cable (09808-03000) (9) Precautions when handling battery (10) Caution for engine running (09667-03001) (11) Caution for approach when machine moving (09812-13000)
Page 25 SAFETY SAFETY LABELS (12) Prohibition of jump start (09842-A0481) (13) Caution for ROPS (09620-B2000) (14) Caution for FOPS (09620-C2000)
Page 26: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES q Only trained and authorized personnel can operate and maintain the machine. q Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
Page 27: Safety Features
SAFETY GENERAL PRECAUTIONS SAFETY FEATURES q Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. q Understand the method of use of safety features and use them properly. q Never remove any safety features.
Page 28: Handrails And Steps
SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. q Use the handrails and steps marked by arrows (A) in the diagram when getting on or off the machine. q The handrail marked by arrow (B) in the diagram is provided to support yourself when refilling the fuel tank with the fuel.
Page 29: No People On Attachments
SAFETY GENERAL PRECAUTIONS NO PEOPLE ON ATTACHMENTS Never let anyone ride on the work equipment, or other attachments. There is a hazard of falling and suffering seri- ous injury. CRUSHING OR CUTTING PREVENTION The clearance around the work equipment will change according to the movement of the link. If you get caught, this may lead to serious personal injury.
Page 30: Fire Prevention
SAFETY GENERAL PRECAUTIONS FIRE PREVENTION q Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particu- larly flammable and can be hazardous. To prevent fire, always observe the following: q Do not smoke or use any flame near fuel or oil. q Stop the engine before refueling.
Page 31: Action If Fire Occurs
If ROPS 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 Komatsu contact your distributor for advice of the method of repair.
Page 32: Safety At Worksite
SAFETY GENERAL PRECAUTIONS SAFETY AT WORKSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. q When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating. q Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Page 33: Ensure Good Visibility
SAFETY GENERAL PRECAUTIONS q If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone come close to the machine.
Page 34: Be Careful About Asbestos Dust
Do not allow other persons to approach during the opera- tion. q Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2-17...
Page 35: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment con- trol lever, do not start the engine or touch the levers . CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. q Remove all dirt from the surface of the window glass to ensure a good view.
Page 36: Precautions In Cold Areas
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS IN COLD AREAS q Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
Page 37: Operation
SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. q Always fasten your seat belt. q Check the operation of travel, steering and brake systems, and work equipment control system.
Page 38: Traveling On Slopes
SAFETY PRECAUTIONS FOR OPERATION q Avoid traveling over obstacles when possible. If the machine has to travel over an obstacle, keep the work equipment close to the ground and travel at low speed. Never travel over obstacles which make the machine tilt strongly to one side.
Page 39: Operate Carefully On Snow
SAFETY PRECAUTIONS FOR OPERATION OPERATE CAREFULLY ON SNOW q Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 40: Transportation
PRECAUTIONS FOR OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 41: Battery
SAFETY PRECAUTIONS FOR OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. q Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 42: Starting With Booster Cable
SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLE If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. q When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the opera- tor's seat and the other working with the battery).
Page 43: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING WHEN TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec- tion or inspection of the wire rope. For towing method, see section “MACHINE TOWING METHOD (3-132)“. q Always wear leather gloves when handling wire rope.
Page 44: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG q Always attach the “DO NOT OPERATE“ warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 45: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE q Set work equipment lock lever (1) and parking barke lever (2) to the LOCK position (L). q Put blocks under the track to prevent the machine from moving. TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running.
Page 46: Proper Tools
Do not hit or roll the accumulator, or subject it to any impact. q When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. NO UNAUTHORIZED PERSONNEL INTO AREA Only authorized personnel can service and repair the machine.
Page 47: Work Under The Machine
SAFETY PRECAUTIONS FOR MAINTENANCE WORK UNDER THE MACHINE q If it is necessary to go under the work equipment or the machine to carry out service and maintenance, support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine.
Page 48: Precautions When Using High-Pressure Grease To Adjust Track Tension
If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work. PRECAUTION WITH HIGH-PRESSURE OIL The hydraulic system is always under internal pressure.
Page 49: Handling High-Pressure Hoses
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 50: Operation
OPERATION...
Page 51: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Machine equipped with cab Machine equipped with canopy Blade Pivot shaft Angle cylinder Track frame Lift cylinder ROPS canopy (10) Idler Track shoe (11) Canopy Sprocket...
Page 52: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Machine equipped with cab Parking brake lever (13) Starting switch Work equipment lock lever (14) Information switch Cigarette lighter (15) Buzzer cancel switch Fuel control dial (16) Brake pedal Steering, forward-reverse, gear shift lever (17) Decelerator pedal Auto shift down switch...
Page 53 OPERATION GENERAL VIEW Machine equipped with canopy Parking brake lever (10) Fan rotation selector switch Work equipment lock lever (11) Information switch Fuel control dial (12) Buzzer cancel switch Steering, forward-reverse, gear shift lever (13) Starting switch Auto shift down switch (14) Brake pedal Preset mode switch...
Page 54 OPERATION GENERAL VIEW MONITOR PANEL Display panel A Filter/oil replacment interval lamp (Speed range display, Engine speed) (10) Warning lamp Power train oil temperature gauge (11) Engine coolant temperature caution lamp Engine coolant temperature gauge (12) Maintenance caution lamp Hydraulic oil temperature gauge (13) Engine preheating pilot lamp Fuel level gauge...
Page 55: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. FRONT PANEL Emergency caution group Lamp...
Page 56: Check Monitor System
Stop the engine, then turn the starting switch to the ON position and check that the lamps light up for approx. 2 seconds. If they do not light up, please ask your Komatsu distributor to carry out inspec- tion.
Page 57: Emergency Caution Items
OPERATION EXPLANATION OF COMPONENTS EMERGENCY CAUTION ITEMS CAUTION If any of the caution lamps begins to flash, stop the engine or reduce the engine speed to low idling imme- diately and check the trouble spot for necessary actions. These items must be monitored when the engine is running. If there is any problem, the caution lamp for the loca- tion of the problem and warning lamp (A) flash, and the alarm buzzer sounds intermittently.
Page 58 OPERATION EXPLANATION OF COMPONENTS ENGINE COOLANT TEMPERATURE CAUTION LAMP This lamp (2) indicates a raise in the coolant temperature. When the monitor lamp flashes, run the engine at low idling speed until green range of the engine coolant temperature gauge lights. POWER TRAIN OIL TEMPERATURE CAUTION LAMP This lamp (3) indicates a rise in the oil temperature of the torque converter outlet.
Page 59: Caution Items
OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If these caution lamps item flash, check and repair the appropriate location as soon as possible. These are items which need to be observed when the engine is running. If any problem occurs, the item needing immediate repair is displayed.
Page 60 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE CAUTION LAMP This lamp (2) lights up for approx. 30 seconds after the starting switch is turned to the ON position if the filter or oil replacement interval has been reached. After replacing the indicated filter or oil displayed on display panel B (multi-information), reset the interval.
Page 61: Meter Group
OPERATION EXPLANATION OF COMPONENTS METER GROUP Engine coolant temperature gauge Engine preheating pilot lamp Power train oil temperature gauge Display panel A Hydraulic oil temperature gauge (Speed range display, Engine speed) Fuel level gauge Display panel B (multi-information) ENGINE COOLANT TEMPERATURE GAUGE NOTICE If the coolant temperature gauge often enters red range (C), check the radiator for clogging.
Page 62 OPERATION EXPLANATION OF COMPONENTS POWER TRAIN OIL TEMPERATURE GAUGE NOTICE If the power train oil temperature gauge often enters the red range (C), we recommend you to lower the travel speed one range (for example, F2 → F1) to reduce the load on the power train when operating. Gauge (2) indicates the torque converter outlet oil temperature.
Page 63 OPERATION EXPLANATION OF COMPONENTS FUEL LEVEL GAUGE Gauge (4) fuel level in the fuel tank. During normal operation, the green range (B) should be lighted If red range (A) lights up during operation, add fuel immedi- ately. (A): Red range (B): Green range REMARK The display is not proportional to the amount of fuel remaining.
Page 64 OPERATION EXPLANATION OF COMPONENTS DISPLAY PANEL B (multi-information) The top and bottom lines in display panel B (multi-information) display information related to the condition of the machine. The content of the display is divided into “OPERATING MODE“ and “MAINTENANCE MODE“. Use the buzzer cancel switch to switch between the operating mode and maintenance mode.
Page 65 OPERATION EXPLANATION OF COMPONENTS Maintenance mode This displays various types of information related to mainte- nance of the machine. For details, see “METHOD OF USING MAINTENANCE MODE (3-24)“. 3-16...
Page 66: Lamps
OPERATION EXPLANATION OF COMPONENTS LAMPS Warning lamp Fan operation confirmation lamp Filter/oil replacement interval lamp WARNING LAMP (Red) NOTICE If alarm buzzer sounds, stop work immediately and perform inspection and maintenance of the appropri- ate point. This lamp (1) flashes when the caution lamp flashes and when an action code is displayed on display panel B (multi-informa- tion).
Page 67 OPERATION EXPLANATION OF COMPONENTS FILTER/OIL REPLACEMENT INTERVAL LAMP (Yellow) If it is time to replace a filter or change the oil, this lamp (2) lights up or flashes for approx. 30 seconds after the starting switch is turned ON. REMARK This lamp (2) lights up if there is less than 30 hours remaining until replacement, and flashes when the replacement interval has passed.
Page 68: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Machine equipped with cab Machine equipped with canopy Starting switch Rear lamp switch Auto shift down switch Fan rotation selector switch Preset mode switch Information switch Head lamp switch Buzzer cancel switch 3-19...
Page 69 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (1) is used to start or stop the engine. (A): OFF position At this position, the starting switch key can be inserted and removed. When the switch is turned to this position, all the electric circuits are turned off and the engine stops.
Page 70 OPERATION EXPLANATION OF COMPONENTS HEAD LAMP SWITCH This switch (4) lights up when the front lamp, and panel lamp light up. ○ (OFF) position: Lights out (ON) position: Lights on REAR LAMP SWITCH This switch (5) lights up the rear lamps. ○...
Page 71 OPERATION EXPLANATION OF COMPONENTS FAN ROTATION SELECTOR SWITCH This switch (6) is used to switch the direction of rotation of the cooling fan. ○ position : Normal rotation Normally use this position. The air is pushed out to the front through the radiator mask. The speed of the fan changes to match the temperature of the coolant in order to improve the cooling efficiency.
Page 72 OPERATION EXPLANATION OF COMPONENTS INFORMATION SWITCH This switch (7) is used to operate display panel B (multi-infor- mation). When the switch is released, it returns automatically to the cen- ter position. When display panel B (multi-information) is in the operation mode turn the switch to <...
Page 73: Method Of Using Maintenance Mode
OPERATION EXPLANATION OF COMPONENTS METHOD OF USING MAINTENANCE MODE To switch from the operation mode to the maintenance mode, turn the buzzer switch to the position and hold it there for at least 2.5 seconds. The screen will switch to the maintenance mode.
Page 74 OPERATION EXPLANATION OF COMPONENTS METHOD OF SELECTING EACH MODE 3-25...
Page 75 If the controllers or monitor panel are replaced, the timer for this function will not work properly. Contact your Komatsu distributor for replacement. In the oil and filter maintenance mode, the replacement inter- vals for oil and filters are displayed on display panel B (multi- information).
Page 76 OPERATION EXPLANATION OF COMPONENTS When the oil or filter has been replaced, select the applicable item, then operate the buzzer cancel switch to The screen will ask if you want to display the replacement his- tory. Operate the information switch to select YES, then operate the buzzer cancel switch to .
Page 77 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING PM CLINIC AUXILIARY MODE CAUTION When moving the work equipment or setting the transmission to the travel position for carrying out mea- surements, check carefully that the situation is safe. The PM clinic auxiliary mode displays the engine speed on display panel B (multi-information). Display panel B (Malti-information) displays the item on the top line (1) and the measured value on the bottom line (2).
Page 78 When any disconnection or short circuit in any sensor is detected, the location and fault code are displayed by a 6- digit code on display panel B (multi-information). When contacting your Komatsu distributor, inform your distributor of the code at the same time.
Page 79 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING USER ADJUST MODE With the user adjust mode, the brightness of the panel screen backlighting and the contrast of the liquid crystal panel can be changed. 1. Adjusting backlighting of liquid crystal display 2.
Page 80 OPERATION EXPLANATION OF COMPONENTS 5. Adjusting backlighting of display panel B (multi-information) 6. The diagram on the right is the mode for adjusting the brightness of the backlighting of the display panel B (multi- information). On the screen, operate the buzzer cancel switch to switch to the screen for adjusting the brightness.
Page 81 OPERATION EXPLANATION OF COMPONENTS 9. Adjusting contrast of liquid crystal display panel B (multi-information) 10. The diagram on the right is the mode for adjusting the con- trast of the liquid crystal display panel B (multi-information). On this screen, operate the buzzer cancel switch to switch to the screen to adjust the contrast.
Page 82: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Machine equipped with cab Machine equipped with canopy Fuel control dial Wiper switch Horn switch Cigarette lighter Room lamp switch Accessory socket Additional working lamp switch (if equipped) Rear glass heating switch (if equipped) 3-33...
Page 83 OPERATION EXPLANATION OF COMPONENTS FUEL CONTROL DIAL Dial (1) is used to control the engine speed and output. (a) Low idling position: Turn fully to the left (b) High idling position: Turn fully to the right HORN SWITCH The horn sounds when the button (2) at the rear of the blade control lever at the right side of the operator's seat is pressed.
Page 84 OPERATION EXPLANATION OF COMPONENTS WIPER SWITCH This switch (5) activates the wipers. The wiper switches are as follows. (A): Left door (LH) (B): Front window (FF) (C): Right door (RH) (D): Rear window (RR) (E): Wiper intermittent operation switch (INT) This is also used as the window washer switch.
Page 85 OPERATION EXPLANATION OF COMPONENTS CIGARETTE LIGHTER This lighter (6) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its origi- nal position after a few seconds, so take it out to light your cig- arette.
Page 86: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Work equipment lock lever Brake pedal Parking brake lever Decelerator pedal Steering, forward-reverse, gear shift lever Blade control lever WORK EQUIPMENT LOCK LEVER WARNING q When leaving the operator's compartment, set the work equipment lock lever securely to the LOCK position.
Page 87 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE LEVER WARNING q When parking the machine, always set the parking brake lever in the LOCK position. q If the parking brake lever is operated, the brake is applied, even when the machine is traveling. The machine will suddenly stop, so this is dangerous.
Page 88 OPERATION EXPLANATION OF COMPONENTS Gear shifting When UP switch (U) or DOWN switch (D) is pushed, the trans- mission speed will change. UP switch (U): Each time the switch is pressed, the transmis- sion will up shift one speed. DOWN switch (D): Each time the switch is pressed, the trans- mission will down shift one speed.
Page 89 OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING Do not place your foot on this pedal unnecessarily. Depress the pedal (4) to apply the right and left brakes. DECELERATOR PEDAL WARNING q Do not place your foot on this pedal unnecessarily. q When passing over the top of a hill or when a load is dumped over a cliff, the load is suddenly reduced, so there is danger that the travel speed will also increase suddenly.
Page 90 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER POWER ANGLE, POWER TILTDOZER This lever (6) is used to lift, tilt or angle the blade. q Lifting control (A) RAISE: Blade goes up (B) HOLD: Blade is stopped and held in this position. (C) LOWER: Blade goes down (D) FLOAT: Blade will move freely according to external force.
Page 91 OPERATION EXPLANATION OF COMPONENTS q Angling control Turn the knob to the right or left to angle the blade. (G) LEFT ANGLE (B) HOLD: Blade is stopped and held in this position. (H) RIGHT ANGLE REMARK When performing only angling operation, be sure to set the lever in the HOLD position and turn the knob to the right or left.
Page 92 OPERATION EXPLANATION OF COMPONENTS POWER TILTDOZER This lever (6) is used to lift or tilt the blade. q Lifting control (A) RAISE: Blade goes up (B) HOLD: Blade is stopped and held in this position. (C) LOWER: Blade goes down (D) FLOAT: Blade will move freely according to external force.
Page 93: Circuit Breaker
OPERATION EXPLANATION OF COMPONENTS CIRCUIT BREAKER NOTICE q When resetting the circuit breaker, always turn off the power first (turn the starting switch OFF). q If the reset button for the circuit breaker comes out immediately when it is pushed in, it is necessary to carry out an inspection of the electrical circuit.
Page 94: Fuse
OPERATION EXPLANATION OF COMPONENTS FUSE NOTICE Before replacing a fuse, be sure to turn starting switch to the OFF position. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 95 OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND CIRCUIT NAME Fuse box (A) Fuse Circuit capacity Reserve Horn, Heater relay Air suspension seat (OPT) Front lamp, Rear lamp Controller Continuous power source Fuse box (B) Fuse Circuit capacity Monitor panel PPC lock S/W Air conditioner Backup alarm Body power source...
Page 96: Fusible Link
OPERATION EXPLANATION OF COMPONENTS FUSIBLE LINK If the electrical equipment in the cab does not work or the battery is not charged, there is probably a disconnection in the fusible link assembled in the wiring harness, so carry out inspection and replace if necessary. REMARK A fusible link refers to the large-sized fuse wiring installed in the high current flow portion of the circuit to protect electrical components and wiring from burning, similar to an ordinary fuse.
Page 97: Electric Power Take-Out Adapter
OPERATION EXPLANATION OF COMPONENTS ELECTRIC POWER TAKE-OUT ADAPTER MACHINE EQUIPPED WITH CAB NOTICE The power for the cigarette lighter is 24V. Do not use it as the power source for 12V equipment. The cigarette lighter socket (1) can be used as a power source for 24V equipment and the accessory socket (2) can be used for 12V equipment.
Page 98: Door - Open Lock
OPERATION EXPLANATION OF COMPONENTS DOOR - OPEN LOCK (Machines equipped with cab) Use this when your want to keep the door held open. 1. Push the door against the door catch (1). The door will be held by the door catch. 2.
Page 99: Cap, Cover With Lock
OPERATION EXPLANATION OF COMPONENTS CAP, COVER WITH LOCK Use the starting switch key to open and close the caps and covers. For their locations , see “LOCKING (3-116)“. Insert the key as far as it will go, then turn it. If the key is turned before it is inserted fully, it may break.
Page 100: Method Of Opening And Closing Cover With Lock
OPERATION EXPLANATION OF COMPONENTS METHOD OF OPENING AND CLOSING COVER WITH LOCK TO OPEN THE COVER (LOCKED COVER) 1. Insert the key into the key slot. 2. Turn the key counterclockwise in direction (A), then pull the cover knob to open the cover. TO LOCK THE COVER 1.
Page 101: Door Pocket
OPERATION EXPLANATION OF COMPONENTS DOOR POCKET (Machines equipped with cab) This is inside the left and right doors. Use it for storing the Operation and Maintenance Manual or other things. Do not put heavy tools or other heavy objects in it. If the pocket is dirty, turn 4 clips (1), then remove the pocket and rinse it.
Page 102: Ashtray
OPERATION EXPLANATION OF COMPONENTS ASHTRAY This is on the left side of the operator's seat. Always make sure that you extinguish the cigarette before clos- ing the lid. TOOL BOX The tool box is inside the battery check cover at the rear left. Keep the tools in this box.
Page 103: Car Stereo, Handling
OPERATION EXPLANATION OF COMPONENTS CAR STEREO, HANDLING (Machine equipped with cab) (If equipped) EXPLANATION OF COMPONENTS Power switch/volume Cassette door Auto-store/preset scan button Fast-forward, rewind buttons Bass control knob (10) Preset buttons Treble control knob (11) Metal tape button Loudness button (12) Manual tuning buttons Time/radio display selector button...
Page 104 OPERATION EXPLANATION OF COMPONENTS POWER SWITCH/VOLUME Turn this knob (1) to the right until it clicks to turn the power on. Turn it further to increase the volume. AUTO-STORE/PRESET SCAN BUTTON Use this button (2) to actuate the preset scan and auto-store functions.
Page 105 OPERATION EXPLANATION OF COMPONENTS BASS CONTROL KNOB Turn this button (3) to the left to reduce the low tones; turn it to the right to emphasize the low tones. Direction (a): Low tone reduced Direction (b): Low tone emphasized TREBLE CONTROL KNOB Turn this button (4) to the left to reduce the low tones;...
Page 106 OPERATION EXPLANATION OF COMPONENTS q Correcting the time Press the button to set the time display. (A) Correcting hour: Keep the DISP button pressed and press the bottom (H) of the TUNING button to correct the hour. (B) Correcting minute: Keep the DISP button pressed and press the top (M) of the TUNING button to correct the minute.
Page 107 OPERATION EXPLANATION OF COMPONENTS PRESET BUTTONS These buttons (10) are used to call up the broadcast station frequencies preset in memory for each of buttons No. 1 to No. It is possible to preset 18 stations (FM: 12; AM: 6) with these buttons.
Page 108 OPERATION EXPLANATION OF COMPONENTS BAND SELECTOR BUTTON When this button (14) is pressed, the band is switched between FM1, FM2, and MW (AM). The band is shown on the display. 3-59...
Page 109: Method Of Operation
OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION METHOD OF SETTING PRESET BUTTONS It is possible to preset 6 MW (AM) stations and 12 FM stations (FM1: 6 stations, FM2: 6 stations). REMARK If you are playing the cassette, press the tape eject button to stop the tape. METHOD OF AUTO PRESET 1.
Page 110 OPERATION EXPLANATION OF COMPONENTS LISTENING TO RADIO 1. Turn the starting switch ON, then turn power switch (1) ON. 2. Use band selector button (2) to select MW (AM), FM1 or FM2. 3. Select the station with the preset buttons (3). REMARK In case you do not promptly remember the number assigned to a certain preset station, press auto-store/preset scan button (4)
Page 111: Precaution When Using
If the sound cannot be heard, nothing is displayed, or any other abnormality occurs, turn off the power switch and ask your Komatsu distributor to make repairs without delay. q Stow the antenna when traveling in places with low overhead clearance.
Page 112: Air Conditioner, Handling
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER, HANDLING (Machine equipped with cab) (If equipped) By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it pos- sible to provide a pleasant working environment even on dusty jobsites. GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL Fan switch Temperature control switch...
Page 113 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidi- fying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
Page 114 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH The temperature can be adjusted with this switch (4) gradually from low temperature to high temperature. The temperature level indicator lamps (A) light up to display the temperature of the air coming from the vents. The more blue lamps on, the lower the temperature is.
Page 115: Method Of Operation
OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION SwitchsCondition of Air conditioner Temperature FRESH/RECIRC Fan switch switch control switch selector switch Rapid All blue RECIRC Cooling More than half Normal HI - LO FRESH are blue Dehumidifying, heat- More than half HI - LO FRESH are red...
Page 116: Precaution When Using Air Conditioner
OPERATION EXPLANATION OF COMPONENTS PRECAUTION WHEN USING AIR CONDITIONER PRECAUTION WHEN USING COOLING OPERATION q If you smoke when using the air conditioner, your eyes may start to itch or burn. Ventilate the cab ever so often to remove the smoke. q When using the air conditioner for a long period of time, carry out ventilation process at least once every hour.
Page 117: Cleaning Air Filter
OPERATION EXPLANATION OF COMPONENTS CLEANING AIR FILTER If the air filter for the FRESH or RECIRC air intake becomes clogged, the cooling or heating capacity will drop. To prevent this, clean the air filter with compressed air once a week. For details of the cleaning method, see “WHEN REQUIRED (4-19)“.
Page 118: Accumulator, Handling
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work carried out.
Page 119 OPERATION EXPLANATION OF COMPONENTS 3-70...
Page 120 OPERATION EXPLANATION OF COMPONENTS 3-71...
Page 121: Operation
Check carefully, and if any problem is found, repair it or contact your Komatsu distributor. q Do not get on or off the machine from the rear. Using this position is dangerous because it is easy to slip and you cannot be seen from the operator's compartment.
Page 122 OPERATION OPERATION 6. Check for problems in handrails, steps, loose bolts. If any problem is found, repair it. Tighten any loose bolts. 7. Check for problems in gauges and monitor Check that there is no problem in the gauges and monitor in the operator's cab. If any problem is found, replace the parts.
Page 123: Check Before Starting
OPERATION OPERATION CHECK BEFORE STARTING Always check the items in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD COOLANT WARNING q Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the subtank.
Page 124 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 125 OPERATION OPERATION CHECK DUST INDICATOR 1. Open engine side cover on the left side of machine. 2. Check if a yellow piston in the display of dust indicator (1) has moved into the red area (7.5 kPa). 3. If the yellow piston has already moved into the red area (7.5 kPa), either clean the filter element or replace it with new one immediately.
Page 126 If the circuit breakers are activated and the fuses are blown frequently or there is a trace of short-circuit- ing in the wirings, check the cause immediately and either correct it by yourself or call your Komatsu dis- tributor for the repair.
Page 127 2. Check that the distance of travel (A) at the center of the pedal is 70 to 90 mm (2.8 to 3.5 in). 3. When this value exceeds 91 mm (3.6 in), or the brake fails to work, please contact your Komatsu distributor for adjust- ment. CHECKING WITH MACHINE MONITOR 1.
Page 128 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand. Fuel is highly flammable and dangerous.
Page 129 Check that the head lamp, rear lamp, additional working lamp (if equipped), and instrument lamp light up normally and they are free from stain and damage. If the lamps do not light, check for a broken bulb or disconected wire, contact your Komatsu distributor for repairs. 1. Turn starting switch to the ON position (B).
Page 130 CHECK OF OPERATION OF BACKUP ALARM Check that the backup alarm sounds normally. If it does not, a defect or broken wire is suspected, ask your Komatsu distributor for possible repairs. 1. Turn starting switch to the ON position (B).
Page 131: Adjustment
OPERATION OPERATION ADJUSTMENT ADJUST OPERATOR'S SEAT WARNING When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK position to prevent any accidental contact with the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 132 OPERATION OPERATION (D) Seat angle adjustment q Front angle adjustment of seat (5 stages) To raise the front of the seat, apply your weight to the seatback, while pulling up lever (4). To lower the front of the seat, apply your weight to the front of the seat, while pulling up lever (4). q Rear angle adjustment of seat (5 stages) To raise the rear of the seat, stand up on your feet a little, while pulling up lever (5).
Page 133 OPERATION OPERATION FASTENING AND REMOVING SEAT BELT WARNING q Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there is any wear or damage, replace. q Even if there appears to be no problem in the seat belt, replace the seat belt once every 3 years. The date of manufacture is woven on the reverse side of the belt.
Page 134 OPERATION OPERATION ADJUST MIRROR Loosen nut (1) of the mirror and adjust the mirror to a position where it gives the best view from the operator's seat. In particular, be sure to adjust the mirror so that people at the rear left or right of the machine can be seen clearly.
Page 135 OPERATION OPERATION ADJUST ARMREST The height of the armrest on the left and right sides of the operator's seat can be adjusted to 3 positions. After adjusting the operator's seat, adjust the armrest to a suitable height. ADJUST ARMREST (RIGHT) Armrest (1) on the right side of the operator's seat can be adjusted in 3 stages: up 30 mm (1.2 in), standard height (center), or down 25 mm (1.0 in).
Page 136: Operation And Check Before Starting Engine
OPERATION OPERATION OPERATION AND CHECK BEFORE STARTING ENGINE WARNING When starting the engine, check that the work equipment lock lever are placed securely at the LOCK posi- tion. If the work equipment control lever is touched by accident when the engine is started, the work equipment may move unexpectedly and cause serious injury or damage.
Page 137 OPERATION OPERATION 3. Check that the blade is lowered to the ground and that blade control lever (3) is in the HOLD position (B). 4. Check that the work equipment lock lever (4) is LOCK posi- tion (L). 3-88...
Page 138: Starting Engine
OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING q Sit down in the operator's seat before starting the engine. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 139 OPERATION OPERATION 3. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position (B). 3-90...
Page 140: Starting In Cold Weather
OPERATION OPERATION STARTING IN COLD WEATHER WARNING q Start the engine only after sitting down in the operator's seat. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. q Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 141 OPERATION OPERATION 3. Check that engine pre-heating pilot lamp (3) on the monitor panel lights up. 4. Maintain the key in the on position until the preheating pilot lamp (3) goes off. 5. When preheating pilot lamp (3) goes off, turn the key of ignition switch (2) to the START position (C) to crank the engine.
Page 142 OPERATION OPERATION 7. When the engine rotation stabilizes, return to the low idle (MIN) position of fuel control dial (1) and then carry out the warming-up operation. REMARK Regardless of the ambient temperature, if the key in starting switch (2) is turned from OFF position to left, preheating pilot lamp (3) will light up and preheating will start.
Page 143: Operations And Checks After Starting Engine
BREAKING IN THE NEW MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life.
Page 144: Starting In Cold Weather
(B). (A): White range (B): Green range (C): Red range 3. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. STARTING IN COLD WEATHER (Ambient temperature below 10°C (50°F)) NOTICE q When the hydraulic oil is at a low temperature, do not carry out operations or move the levers suddenly.
Page 145 If the oil temperature in the power train is not raised properly, it will take longer to accelerate to the maximum speed. 6. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor.
Page 146: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be drastically shortened. Do not abruptly stop the engine except for an emergency. If the engine has overheated, do not stop it abruptly, run it at medium speed allowing the engine to gradually cool down, then stop it.
Page 147: Machine Operation
OPERATION OPERATION MACHINE OPERATION MOVING MACHINE WARNING q When moving the machine, check that the area around the machine is safe, and sound the horn before mov- ing. Do not allow anyone to enter the area around the machine. There is a blind spot at the rear of the machine, so be particularly careful when traveling in reverse.
Page 148 (4) slowly, then release the decelerator pedal gradually. Check that the backup alarm sounds when steering, forward- reverse, gear shift lever (6) is placed in REVERSE position. If the alarm does not sound, please contact your Komatsu distrib- utor. 3-99...
Page 149: Stopping Machine
OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. 1. Depress brake pedal (1) to stop the machine. NOTICE If the brake is depressed when the engine speed or travel speed is high, the brake disc may make a slipping sound. Normally, depress decelerator pedal (2) to reduce the engine speed and travel speed before depressing the brake.
Page 150: Shifting Gears
OPERATION OPERATION SHIFTING GEARS The machine does not have to be stopped to shift gears. 1. Move steering, forward-reverse, gear shift lever (1) to the desired gear position to shift gears. GEARSHIFTING OPERATION When UP switch (U) or DOWN switch (D) is pushed, the trans- mission speed will change.
Page 151: Gearshifting Operation Using Preset Mode Function
OPERATION OPERATION GEARSHIFTING OPERATION USING PRESET MODE FUNCTION If the preset mode function is used, the speed ranges used when the machine travels in forward and reverse can be preset as desired. 1. Set steering, forward-reverse, gear shift lever (1) to the NEUTRAL position (N).
Page 152: Auto Down Shift Operation
OPERATION OPERATION REMARK Even when the preset mode function is being actuated, it is possible to select the speed range by operating the UP switch or DOWN switch when the machine is traveling forward or in reverse. However, the preset mode remains set as it is. If the steering, forward-reverse, gear shift lever is returned to the NEUTRAL position and then operated again to the FORWARD or REVERSE position, the set speed range is selected.
Page 153: Shifting Between Forward And Reverse
Position (F): Forward Position (N): Neutral Position (R): Reverse REMARK Check that the backup alarm sounds when steering, forward- reverse, gear shift lever is placed in REVERSE position. If the alarm does not sound, please contact your Komatsu distributor. 3-104...
Page 154 OPERATION OPERATION 4. Release decelerator pedal (1) and raise the engine speed. REMARK When changing direction between forward and reverse while traveling downhill, depending on the conditions of the machine, to ensure safety, the gear may shift automatically to 1st before shifting to the desired range. For example, when changing from F2 to R2, depending on the conditions, the gear may shift F2 o R1 o R2.
Page 155: Steering Machine
OPERATION OPERATION STEERING MACHINE WARNING q Avoid as much as possible turning the machine on a slope. The machine will tend to slip sideways. Particular care should be taken on soft or clay land. q Never make a pivot turn at high speed. NORMAL TURNING WARNING When performing a counterrotation turn, the feeling of operation when your head is facing the rear is dif-...
Page 156 OPERATION OPERATION WHEN MAKING PIVOT TURN TO LEFT WHILE TRAVELING NOTICE When carrying out a counterrotation turn, if the load is not equal on the left and right sides, the machine may carry out a pivot turn, so check the ground conditions and be careful not to hit any obstacles.
Page 157: Precautions For Operation
OPERATION OPERATION PRECAUTIONS FOR OPERATION PAY ATTENTION TO GAUGES When the red range lights on the power train oil temperature gauge while operating, reduce the load and wait for the temperature to decrease. PERMISSIBLE WATER DEPTH When operating in water, always keep the bottom of carrier roll- ers (1) above the surface of the water.
Page 158: Method Of Using Brakes
OPERATION OPERATION PRECAUTIONS WHEN ENGINE STOPS ON SLOPES If the engine stops while working or traveling on a hill, immediately depress the brake pedal to bring the machine to a complete stop. METHOD OF USING BRAKES The following actions cause premature damage to the brakes, so avoid such operations. q Using emergency brake at full speed q Using brake with engine running at full speed in first gear (F1, R1) (Machine stall condition) REMARK...
Page 159: Work Possible Using Bulldozer
OPERATION OPERATION WORK POSSIBLE USING BULLDOZER In addition to the following, it is possible to further increase the range of applications by using various attachments. DOZING A bulldozer digs and transports dirt in a forward direction. Slope excavation can always be most effectively carried out by proceeding from the top downward.
Page 160: Cutting Into Hard Or Frozen Ground Or Ditching
OPERATION OPERATION CUTTING INTO HARD OR FROZEN GROUND OR DITCHING For digging and ditch excavation of hard or frozen ground, tilt the blade. Even hard ground can be dug effectively by a tilted or angled blade. FELLING TREES, REMOVING STUMPS NOTICE Do not uproot trees or stumps or fell trees by angling or tilting the blade.
Page 161: Adusting Posture Of Work Equipment
OPERATION OPERATION ADUSTING POSTURE OF WORK EQUIPMENT ADJUST ANGLE OF BLADE EDGE (Power tiltdozer only) WARNING It is dangerous if the work equipment moves by mistake when adjusting angle of the blade edge. Set the work equipment in a stable condition, then stop the engine and lock the work equipment securely with the work equipment lock lever.
Page 162: Adjust Amount Of Tilt Power Tilt
OPERATION OPERATION ADJUST AMOUNT OF TILT POWER TILT WARNING When adjusting the amount of tilt, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the work equipment lock lever.
Page 163: Parking Machine
OPERATION OPERATION PARKING MACHINE WARNING q When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, place the parking brake lever in the LOCK posi- tion and insert blocks underneath the track shoes. As an additional safety measure, thrust the blade into the ground.
Page 164: Check After Finishing Work
OPERATION OPERATION 4. Set work equipment lock leve (3) in the LOCK position (L). CHECK AFTER FINISHING WORK BEFORE STARTING ENGINE Use the meters and caution lamps to check the engine coolant temperature, engine oil pressure, fuel level, and Power train oil temperature.
Page 165: Locking
OPERATION OPERATION LOCKING To prevent vandalism, there are locks at the following places. Places that can be locked with the starting switch key. q Top cover at front of chassis (1) q Right and left engine side covers (2) q Battery inspection cover (3) q Inspection cover for fuel tank drain valve(4) q Cab door opener (5) (machines equipped with cab) q Fuel tank filler cap (6)
Page 166: Tips For Longer Undercarriage Life
OPERATION METHOD q Select the track shoe that best suits the type of soil to be encountered in service. Please consult your Komatsu distributor when selecting track shoes. q Do not allow shoe slipping to occur during operation. If shoe slipping occurs, reduce load to the blade until slipping stops.
Page 167: Transportation
If it is necessary to remove the cab for transportation, there is danger that the seal may be damaged when remov- ing or installing the cab, so please contact your Komatsu distributor. When installing the cab, please contact your Komatsu distributor, too.
Page 168: Precautions When Removing Rops
OPERATION TRANSPORTATION 2. Remove the quick coupler (1), then remove the work equipment assembly. 3. Remove the left and right trunnions (2). (For D61PX) REMARK In the case of D61PX, remove the left and right trunnions (2). In the case of D61EX, the width including the left and right trun- nions (2) is within 3.0 m (9 ft 10 in), so there is no need to remove them.
Page 169: Loading, Unloading Work
OPERATION TRANSPORTATION LOADING, UNLOADING WORK WARNING q Since loading and unloading of the machine is dangerous, be extremely careful. q When loading or unloading the machine, operate it slowly with the engine speed low and the transmis- sion in the 1st gear. q Use ramps having sufficient width, length, thickness, and strength.
Page 170 OPERATION TRANSPORTATION 4. Set parking brake lever to the FREE position (F). 5. Set the transmission in the 1st gear and run the engine at low idle. 6. Set the travel direction toward the ramps and drive slowly. 7. The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and the machine is unbalanced and becomes dangerous.
Page 171 OPERATION TRANSPORTATION 5. Fix the machine as explained below so that it will not move during transportation. In particular, fix the machine securely to prevent it from slipping sideways. 6. Put blocks (1) in front and behind the track shoes of both sides.
Page 172 OPERATION TRANSPORTATION UNLOADING WORK 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely and put blocks (1) under the tires to hold the trailer in position.Set gap (3) between ramps (2) to match the distance between the left and right tracks, and keep angle (4) to a maximum of 15°.
Page 173: Lifting Machine
The lifting procedure applies to machines with standard specifications. The method of lifting differs according to attachments and options actually installed on the machine. For the proper lifting procedures, contact your Komatsu distributor. For details of the weight, see “SPECIFICATIONS (5-2)“.
Page 174 OPERATION TRANSPORTATION LIFTING POSITION (For D61EX) q Fit the wire rope at the front to the track shoe within range (A) between the center of the front idler and the rear edge. q Fit the wire ropes at the front to both the left and right track shoes. q Fit protector (1) at the edge to protect the wire rope.
Page 175 OPERATION TRANSPORTATION For machine equipped with ripper q Raise ripper (3) to the maximum height and retract the ripper cylinder fully. q Fit the wire rope at the front to the track shoe within range (A) between the center of the front idler and the rear edge.
Page 176 OPERATION TRANSPORTATION (For D61PX) q Raise blade (5) height (B) 30 - 40 cm (1.2 - 1.6 in) from the ground. q Pass the wire rope at the front within the range (A) between the center of the front idler and the rear edge, pass it under the undercover, and bring it out to the opposite side.
Page 177: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
Page 178 OPERATION COLD WEATHER OPERATION BATTERY WARNING q The battery generates flammable gas. Do not bring fire or sparks near the battery. q Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 179: After Completion Of Work
OPERATION COLD WEATHER OPERATION AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning. Observe the following precautions. q Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rod clean to prevent damage to the seal caused by mud or dirt on the rod surface getting inside the seal together with drops of water.
Page 180: Long-Term Storage
AFTER STORAGE NOTICE If the machine has been stored without the monthly rust prevention operation, consult your Komatsu dis- tributor for service. When using the machine after long-term storage, do as follows before using it. q Wipe off the grease from the hydraulic cylinder rods.
Page 181: Troubleshooting
When returning a towed machine to the jobsite, first check that the necessary repairs and adjustments have been made. For details of the method of towing, please contact your Komatsu distributor. q With this machine, if the engine stops or there is an problem in the hydraulic system and the oil pressure in the brake circuit drops, the brake is actuated and it becomes impossible to move the machine.
Page 182: When It Is Possible To Start Engine
OPERATION TROUBLESHOOTING If the machine gets stuck in the mud or a heavy thing needs to be towed, install a towing wire rope to the draw bar pin. WHEN IT IS POSSIBLE TO START ENGINE CAUTION The operator of the machine being towed should always operate the steering so that the machine faces in the direction of the towing line.
Page 183: When Engine Does Not Start
For details of the equipment needed to tow a machine when the engine does not work, please contact your Komatsu distributor. To release the brakes, install a brake release pump on the machine to be towed and connect the hose at the pres- sure side of the pump to the brake.
Page 184 OPERATION TROUBLESHOOTING PUMP TEST CAUTION If the operation is carried out without inspecting the hydraulic pump, it may lead to damage of the brake system seal. Always inspect the hydraulic pump before connecting it. 1. Install tee (1) to the discharge portion of the pump, then install oil pressure gauge (2) and accumlator (3), rubber hose (4).
Page 185 OPERATION TROUBLESHOOTING CONNECTING PUMP TO MACHINE WARNING q Fit blocks under the tracks to prevent the machine from moving, then release the brake. q Immediately after the engine is stopped, all parts are at high temperature, so do not carry out the oper- ation to install the brake release pump immediately.
Page 186 OPERATION TROUBLESHOOTING RELEASING BRAKE CAUTION When a machine is towed, the brakes must be fully released. If the brakes are partially applied, this may lead to overheating and damage to the brakes. To release the brakes, set the pump pressure to 2.7 to 3.1 MPa (28 to 32 kg/cm2, 398 to 454 PSI). If the pump pressure exceeds 3.1 MPa (32 kg/cm2, 454 PSI), the components of the brake may be dam- aged.
Page 187: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING q It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. q When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position.
Page 188: Precautions For Battery Charging
OPERATION TROUBLESHOOTING PRECAUTIONS FOR BATTERY CHARGING If the battery is charged improperly, it may explode. Accord- ingly, charge it according to “IF BATTERY IS DISCHARGED (3-138)“ and the instruction manual attached to the charger, and observe the following items. q Set the voltage of the charger to match the voltage of the battery to be charged.
Page 189 OPERATION TROUBLESHOOTING NOTICE q The starting system for this machine uses 24V. For the normal machine, also use a 24V battery. q The size of the booster cable and clip should be suitable for the battry size. q The battery of the normal machine must be the same capacity as that of the engine to be started. q Check the cables and clips for damage or corrosion.
Page 190 OPERATION TROUBLESHOOTING DISCONNECTING THE BOOSTER CABLE After the engine has started, disconnect booster cables in the reverse order in which they were connected. 1. Remove the clip of booster cable (B) from engine block (E) on the problem machine. 2. Remove the clip of booster cable (B) from the negative (-) terminal of battery (D) on the normal machine.
Page 191: Other Trouble
TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main cause Remedy Lamp does not glow brightly even •Defective wiring...
Page 192: Monitor Panel
(If no telephone number is set, dis- plays 0) Note: If an abnormality display appears on display panel B, check the fault code. For details, see “METHOD OF USING FAULT CODE DISPLAY MODE (3-29)“. When contacting your Komatsu distributor, please give the fault code also. 3-143...
Page 193: Chassis
OPERATION TROUBLESHOOTING CHASSIS q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy •Improper tightening of oil pipe, pipe •Check, repair...
Page 194: Engine
OPERATION TROUBLESHOOTING ENGINE q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy •Add oil to specified level, see •Engine oil pan oil level is low (suck-...
Page 195 OPERATION TROUBLESHOOTING 3-146...
Page 196 MAINTENANCE...
Page 197: Guide To Maintenance
KOMATSU GENUINE REPLACEMENT PARTS: Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem- perature. ALWAYS USE CLEAN WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 198 MAINTENANCE GUIDE TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: q Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged. q Clean the radiator core frequently to avoid clogging. q Clean and replace the fuel filter frequently. q Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Page 199 MAINTENANCE GUIDE TO MAINTENANCE PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES: q When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and replace with new parts. When doing this, be careful not to forget to assemble the O-rings and gaskets. q When installing the hoses, do not twist or bend them into loops with a small radius.
Page 200: Outline Of Service
When changing the oil, always replace the related filters at the same time. q We recommend you have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor. FUEL q After completing the day's operations, fill the fuel tank to force out any air containing moisture.
Page 201: Coolant
Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair methods.
Page 202: Storing Oil And Fuel
Perform sampling at regular fixed intervals. q Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. STORING OIL AND FUEL q Keep indoors to prevent any water, dirt, or other impurities from getting in.
Page 203: Relating To Electric System
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. q Never install any electric components other than those specified by Komatsu. q External electro-magnetic interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 204 When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check for the latest part number when ordering parts. WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.
Page 205 MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS *1: ASTM D975 No.1 4-10...
Page 206 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add sin- gle grade oil that matches the temperature range in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Page 207 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.) EO10-CD AF-ACL EO30-CD GO90 G2-LI AF-PTL KOMATSU EO10-30CD GO140 G2-LI-S AF-PT(Winter, one EO15-40CD season type) Diesel sigma S super dieselmulti- AGIP Rotra MP GR MU/EP...
Page 208 MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Engine Oil Anti-freeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.)
Page 209 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, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 210 Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose clamps 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 critical parts. SAFETY CRITICAL PARTS Safety critical parts for periodic replacement...
Page 211 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4-16...
Page 212 MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART WHEN REQUIRED Check, clean and replace air cleaner element ....................4-194 Clean inside of cooling system.......................... 4-234 Check track shoe tension, adjust ........................4-264 Check and tighten track shoe bolts ........................4-284 Check electrical intake air heater ........................
Page 213: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 1000 HOURS SERVICE Change oil in power train case, clean strainers (power train strainer, scavenging pump strainer) ....4-584 Check oil level in damper case, add oil ......................4-604 Change oil in final drive case ..........................4-614 Clean breather ..............................
Page 214: When Required
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING q If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. q When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 215 MAINTENANCE SERVICE PROCEDURE 4. Clean the interior of the air cleaner body, cover (3) and evacuator valve (6). NOTICE The inner element must not be used again even after cleaning. When replacing the outer element, replace the inner element at the same time. 5.
Page 216 MAINTENANCE SERVICE PROCEDURE 11. Push the button of dust indicator (1) and return the yellow piston to its original position. 12. Close the left engine side cover. REPLACING ELEMENT 1. Open the left engine side cover. 2. Remove four clips (2), then remove cover (3). 3.
Page 217 MAINTENANCE SERVICE PROCEDURE 9. Push the button of dust indicator (1) and return the yellow piston to its original position. REMARK The yellow piston in the dust indicator may go to a position between 3.7 kPa - 5.0 kPa immediately after the element has been replaced with a new element, but this does not indicate any abnormality.
Page 218: Clean Inside Of Cooling System
MAINTENANCE SERVICE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM WARNING q Just after the engine is stopped, the coolant is still hot and the internal pressure in the radiator is still high. If the radiator cap is removed under this condition, you may scald yourself. Accordingly, wait until the temperature goes down, then loosen the cap slowly to release the pressure.
Page 219 If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once. Use city water for the coolant. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 220 MAINTENANCE SERVICE PROCEDURE 11. Open the engine side cover on the left side of the chassis. 12. Drain the cooling water inside sub-tank (7), clean the inside of the sub-tank, then fill again with cooling water to a point midway between the FULL and LOW marks. 13.
Page 221: Check Track Shoe Tension, Adjust
Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. WHEN INCREASING TENSION Prepare a grease gun.
Page 222 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. 1. Loosen plug (1) gradually to release the grease.
Page 223: Check And Tighten Track Shoe Bolts
Tighten the bolts in the order shown in the diagram on the right. CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections.
Page 224: Reverse And Replace End Bits And Cutting Edges
MAINTENANCE SERVICE PROCEDURE REVERSE AND REPLACE END BITS AND CUTTING EDGES WARNING When carrying out this operation, it is extremely dangerous if the work equipment is moved by mistake. Set the work equipment in a stable condition, stop the engine, and set the work equipment lock lever securely to the LOCK position.
Page 225 MAINTENANCE SERVICE PROCEDURE 6. Remove nut (1) and bolt (2), then replace or reverse the cutting edge and the end bit. 7. Install the cutting edge to the blade and tighten the bolt temporarily. Press the blade against the ground to elimi- nate the play of bolt (2), then tighten the bolt to the speci- fied torque.
Page 226: Clean, Check Radiator Fins
MAINTENANCE SERVICE PROCEDURE CLEAN, CHECK RADIATOR FINS If the radiator fins are clogged or dirty, clean and inspect them. CLEANING BY ROTATING COOLING FAN IN REVERSE DIRECTION NOTICE When rotating the cooling fan in the reverse direction, be extremely careful of flying dust. When stopping the engine when the cooling fan is rotating in the reverse direction, first run the engine at low idling, then stop it.
Page 227 MAINTENANCE SERVICE PROCEDURE 9. Turn the fan rotation selector switch (2) to the normal rotation position (a) and cancel the reverse rotation. 10. After cleaning, inspect the engine room and remove any dirt. CLEANING WITH COMPRESSED AIR WARNING q Directing compressed air, pressurized water, or steam directly at your body, or using these and caus- ing dust to fly may cause personal injury.
Page 228: Check, Adjust Air Conditioner
(C) None: Colorless, transparent REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributors to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 229: Grease Door Hinge
MAINTENANCE SERVICE PROCEDURE GREASE DOOR HINGE (Machines equipped with cab) If the door makes a squeaking noise when it is opened or closed, spray lubricant in through the split in the hinge bushing. If the bushing is worn, replace the hinge. CHECK DOOR LOCK STRIKER (Machines equipped with cab) If wear (A) of the door of lock striker exceeds 0.5 mm (0.02 in),...
Page 230: Check Door Latch
MAINTENANCE SERVICE PROCEDURE CHECK DOOR LATCH (Machines equipped with cab) Hold the door open and check that there is still grease inside the latch. 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 will become poor because of dust inside the latch, and the handle...
Page 231: Replace Wiper Blade
MAINTENANCE SERVICE PROCEDURE REPLACE WIPER BLADE (Machines equipped with cab) If the blade is damaged, it will not wipe the window clean, so replace the blade. REPLACEMENT FRONT, DOOR WIPER 1. It is hooked at portion (A), so move the blade in the direc- tion of the arrow to remove it.
Page 232: Check Idler Oil Level, Add Oil
Tighten plug (4). 3. If any oil does not flow out when plug (4) is removed, the quantity of oil is insufficient. In this case, ask your Komatsu distributor for add oil.
Page 233: Adjust Idler Clearance
Thickness of one shim is 1.0 mm (0.04 in). CHECK LINK PITCH If the measured value comes close to the repair limit, please contact your Komatsu distributor. 1. Insert a wooden block between track shoe and sprocket to take up the slack in track shoes.
Page 234: Check Outside Diameter Of Track Roller
MAINTENANCE SERVICE PROCEDURE CHECK OUTSIDE DIAMETER OF TRACK ROLLER If the measured value comes close to the repair limit, please contact your Komatsu distributor. 1. Measure the height (dimension C) of the link tread as shown in the diagram. 2. Stop machine at position where link tread, whose size C has been measured completely, contacts roller tread.
Page 235: Adjust Play In Center Ball
MAINTENANCE SERVICE PROCEDURE ADJUST PLAY IN CENTER BALL (Power angle, power tiltdozer only) WARNING When adjusting, always set the work equipment lock lever to the LOCK position except when operating the blade. It is necessary to adjust the shim at the center ball in the following cases. q When there is play at the center ball.
Page 236: Lubricating Universal Joint
MAINTENANCE SERVICE PROCEDURE LUBRICATING UNIVERSAL JOINT WARNING The undercover is heavy. Never try to open or close the cover when directly beneath it. When removing bolts(2), carry out the work from the rear of the cover so that you can easily get out of the way. 1.
Page 237: Procedure For Bleeding Air In Hydraulic System
MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM See “STARTING ENGINE (3-89)“. Since the engine must be started and the blade must be operated, see OPERATION. NOTICE If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing.
Page 238: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see “CHECK BEFORE STARTING (3-74)“ in the OPERATION section. q Check coolant level, add coolant q Check oil level in engine oil pan, add oil q Check dust indicator q Check, drain water separator q Check oil level in power train case, add oil q Check electric wiring...
Page 239: Drain Water, Sediment From Fuel Tank
MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE DRAIN WATER, SEDIMENT FROM FUEL TANK Carry out this check before operating the machine. q Prepare a container to catch the fuel that is drained. 1. Open cover (1). 2. Open valve (2) at the bottom of the tank and drain the sed- iment and water that has accumulated at the tank bottom together with fuel.
Page 240: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATING 1. Lower the blade to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 241 MAINTENANCE SERVICE PROCEDURE POWER TILTDOZER (1) Lift cylinder bottom pin (2 places) (2) Lift cylinder head pin (2 places) (3) Lift rod (4 places) (4) Center brace ball joint (2 places) (5) Tilt brace ball joint (1 place) (6) Tilt brace thread (1 place) (7) Lift lever mounting pin (4 places) (8) Tilt cylinder ball joint (1 place) 4-46...
Page 242: Grease Equalizer Bar Side Pin
MAINTENANCE SERVICE PROCEDURE GREASE EQUALIZER BAR SIDE PIN Greasing points Grease fitting (1): Front of carrier roller support on left side of machine Grease fitting (2): Rear of carrier roller support on right side of machine 1. Remove all dirt from the top of the track frame and cover. 2.
Page 243: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. 1.
Page 244: Check Level Of Battery Electrolyte
UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4-49...
Page 245 Neutralize the removed fluid with baking soda (sodium bicar- bonate), then flush it away with a large amount of water or con- sult your Komatsu distributor or battery maker. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
Page 246: Clean Water Separator Strainer
MAINTENANCE SERVICE PROCEDURE CLEAN WATER SEPARATOR STRAINER WARNING q The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before replacing the filter. q Do not bring fire or sparks near the fuel. 1.
Page 247: Check Brake Performance
SERVICE PROCEDURE CHECK BRAKE PERFORMANCE WARNING If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately. NOTICE Do not place the gear shift lever in 1st under any circumstances. The machine will be damaged.
Page 248: Check Air Conditioner Compressor Belt Tension, Adjust
Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. q In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts with new ones.
Page 249: Clean Air Conditioner Air Filter (Fresh/Recirc Filter)
MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (Machines equipped with cab) Clean the air conditioner air filter if it becomes clogged or if there is dirt or oil stuck to it. In places where there is a lot of dust, clean the air filter once a week. In addition, clean the air conditioner air filter at the same time, when cleaning the engine air cleaner.
Page 250: Every 500 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 500 HOURS SERVICE Maintenance for every 50 and 250 hours service should be carried out at the same time. REPLACE FUEL FILTER CARTRIDGE WARNING q The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before replacing the filter.
Page 251: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
(P) slowly and drain the oil. When doing this, be careful not to get oil over yourself. 3. Check the drained oil, and if there are excessive metal par- ticles or foreign material, please contact your Komatsu dis- tributor. 4. Tighten drain valve (P).
Page 252: Replace Corrosion Resistor Cartridge
5. When installing, screw in cartridge until seal comes in contact with sealing surface, then tighten approx. 2/3 turn. 6. Open valve (1). Use Komatsu genuine cartridge. REPLACE POWER TRAIN OIL FILTER ELEMENT WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation.
Page 253: Every 1000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 50, 250 and 500 hours should be carried out at the same time. CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING PUMP STRAINER) WARNING q The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation.
Page 254 MAINTENANCE SERVICE PROCEDURE 6. Loosen mounting bolt (3) of the power train strainer, then remove cover (4). 7. Take out spring (5), then take out strainer (6). 8. Remove all dirt from strainer (6), then wash in clean diesel oil or flushing oil. Clean the case interior and the removed parts.
Page 255: Check Oil Level In Damper Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN DAMPER CASE, ADD OIL WARNING q The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. q The undercover is heavy. Never try to open or close the cover when directly beneath it.
Page 256: Change Oil In Final Drive Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN FINAL DRIVE CASE WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. q Refill capacity D61EX: (each) 24 liters (6.34 US gal) D61PX: (each) 27 liters (7.13 US gal) 1.
Page 257: Check All Tightening Parts Of Turbocharger
Check that the bolts are not loose and that there is no damage. If any bolt is loose, tighten it to the following torque. If there is any damage, replace the bolt with a genuine Komatsu part. Tightening torque: 785 to 980 N·m (80 to 100 kgf·m, 578.6 to 723.3 lbft)
Page 258: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Page 259: Replace Hydraulic Tank Breather Element
MAINTENANCE SERVICE PROCEDURE REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING q The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. q When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 260: Change Oil In Damper Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN DAMPER CASE WARNING q The parts and oil is very hot just after the operation. Wait until the oil temperature drops, then start the work. q The undercover is heavy. Never try to open or close the cover when directly beneath it.
Page 261: Clean, Check Turbocharger
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced. CHECK ALTERNATOR, STARTING MOTOR The brushes mat be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspec- tion and repairs.
Page 262: Every 4000 Hours Service
Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be carried out at the same time. CHECK WATER PUMP Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any abnormality is found, please contact your Komatsu distributor for repairs or replacement. 4-67...
Page 263 MAINTENANCE SERVICE PROCEDURE 4-68...
Page 264: Specifications
SPECIFICATIONS...
Page 265 Power angle power tiltdozer, ROPS guard, cab, air conditioner Item Unit D61EX-15 D61PX-15 Machine weight kg (lb) 16,840 (37,132) 18,460 (40,704) Name of engine Komatsu SA6D114E-2 diesel engine Engine horsepower kW(HP)/rpm 116(155)/1,800 A Overall length mm (ft in) 5,030 (16'6“) 5,465 (17'11“) B Overall height mm (ft in) 3,150 (10'4“)
Page 266: Attachments, Options
ATTACHMENTS, OPTIONS...
Page 267: General Precautions
GENERAL PRECAUTIONS PRECAUTIONS RELATED TO SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distribu- tor first.
Page 268: Handling Hydraulic Ripper
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER HANDLING HYDRAULIC RIPPER q This ripper is applicable for the D61EX. q When installing it to the D61PX, change the track shoes to 600 mm (23.6 in) narrow single shoes. If the ripper is operated on a machine equipped with wider track shoes, there is danger that the ripper will damage the undercarriage.
Page 269: Explanation Of Components
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER WARNING When carrying out inspection or maintenance of the machine, or when parking the machine, lower the rip- per to the ground and set the work equipment lock lever to the LOCK position. This lever is used to operate the ripper.
Page 270: Operation
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER OPERATION CHECK BEFORE STARTING ENGINE, ADJUST WALK-AROUND CHECK 1. Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the rivets. If any abnormality is found, replace or repair. PRECAUTIONS WHEN OPERATING q Travel in low speed and lower the ripper gradually when starting to move the machine off.
Page 271 ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER When changing the digging depth, do as follows. 1. Remove cotter pin (1). 2. Remove pin (2), change the position of the shank hole, then insert pin (2). 3. Insert cotter pin (1). ADJUSTING DIGGING ANGLE Adjust the position of the mounting pin hole in the beam and upper link.
Page 272: Troubleshooting
HANDLING HYDRAULIC RIPPER TROUBLESHOOTING OTHER TROUBLE q ( ): Always contact your Komatsu distributor when dealing with these items. q In cases of problem or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Slow ripper raising and function, •Add oil to specified level, see...
Page 273: Maintenance
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER MAINTENANCE EVERY 250 HOURS SERVICE LUBRICATING 1. Lower the ripper to the ground and stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3. After greasing, wipe off any old grease that was pushed out. (1) Ripper cylinder foot pin (1 place) (2) Ripper cylinder rod end pin (1 place) (3) Link pin (8 places)
Page 274: Air Suspension Seat
ATTACHMENTS, OPTIONS AIR SUSPENSION SEAT AIR SUSPENSION SEAT ADJUSTMENT WARNING When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK position to prevent any accidental contact with the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 275 ATTACHMENTS, OPTIONS AIR SUSPENSION SEAT (C) Adjusting seat height The seat height adjustment uses an air system, and it can be adjusted steplessly. When adjusting the height, pull lever (3) up fully or push it down fully (when pulling it up, pull it until a click is felt). When the seat is set at the desired height, release the lever.
Page 276 ATTACHMENTS, OPTIONS AIR SUSPENSION SEAT (G) Adjusting headrest angle Rotate the backrest to the front or rear and set to the desired angle. Amount of adjustment: 38 degrees (H) Adjusting headrest height Move the headrest up or down and set to the desired height. Amount of adjustment: 100 mm (3.9 in) (I) Lumbar support Operate switch (6) to give a suitable tension to the lumbar region.
Page 277: Deluxe Seat
ATTACHMENTS, OPTIONS DELUXE SEAT DELUXE SEAT (Rotating seat) ADJUSTMENT WARNING When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK position to prevent any accidental contact with the control levers. q Always adjust the operator's seat before starting each operation or when the operators change shift. q When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 278 ATTACHMENTS, OPTIONS DELUXE SEAT (D) Height adjustment of seat q Turn lever (4) to adjust the height of the seat. q If the lever is turned clockwise, the seat is heightened. If the former is turn counterclockwise, the latter is low- ered.
Page 279: Headrest
ATTACHMENTS, OPTIONS HEADREST HEADREST Removal of headrest Pull up the headrest. REMARK The headrest cannot be fixed to halfway. 6-14...
Page 280: Equipping Fire Extinguisher And First-Aid Kit
ATTACHMENTS, OPTIONS EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT Equipping the fire extinguisher and the first-aid kit at the illustrated position needs brackets (if equipped). The fire extinguisher and the first-aid kit can be installed to the positions shown in the following illustration. (1) First-aid kit (2) Fire extinguisher For parts that are required to install them in your machine,...
Page 281 ATTACHMENTS, OPTIONS EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT 6-16...
Page 282 INDEX INDEX <A> GUIDE TO MAINTENANCE ........4-2 ACCUMULATOR, HANDLING......3-69 ADUSTING POSTURE OF WORK EQUIPMENT..3- <H> HANDLING HYDRAULIC RIPPER ......6-3 AIR CONDITIONER, HANDLING ......3-63 EXPLANATION OF COMPONENTS ....6-4 GENERAL LOCATIONS AND FUNCTION OF GENERAL VIEW..........6-3 CONTROL PANEL ..........
Page 283 INDEX PERIODIC REPLACEMENT OF SAFETY CRITICAL MACHINE TOWING METHOD ..... 3-132 PARTS.............4-15 OTHER TROUBLE........3-142 POSITION OF SERVICE METER......1-9 TRQUE LIST............4-14 PRECAUTIONS FOR MAINTENANCE ....2-27 PRECAUTIONS FOR OPERATION ..2-18,3-108 <U> BATTERY ............2-24 USE OF FUEL, COOLANT AND LUBRICANTS OPERATION ...........2-20 ACCORDING TO AMBIENT TEMPERATURE4-10 STARTING ENGINE........2-18 PROPER SELECTION OF FUEL, COOLANT AND...
Page 284 COLOPHON...

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Komatsu Galeo D61EX-15 Operation & Maintenance Manual

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Maintenance Schedule Chart 4

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Troubleshooting

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