Page 2 FOREWORD...
Page 3 If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and speciffications that are necessary for use in your country.
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 works: Dozing Smoothing Cutting into hard or frozen ground or ditching. Felling trees, removing stumps See the section "WORK POSSIBLE USING BULLDOZER (PAGE 3-77)" 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. MACHINE SERIAL NO. PLATE AND POSITION This is at the front bottom right of the operator's seat. ENGINE SERIAL NO. PLATE AND POSITION...
Page 10: Position Of Service Meter
FOREWORD NECESSARY INFORMATION POSITION OF SERVICE METER This is at the left upper part of the monitor panel. TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Distributor name Address Service Personal Phone/Fax...
Page 11: Table Of Contents
FOREWORD 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 MACHINE SERIAL NO. PLATE AND POSITION ..................1-8 ENGINE SERIAL NO. PLATE AND POSITION ..................1-8 POSITION OF SERVICE METER ......................1-9 TABLE OF ENTER SERIAL NO.
Page 12 FOREWORD CONTENTS CONTROL LEVERS AND PEDALS ......................3-15 FUSE ................................ 3-22 ELECTRIC POWER TAKE-OUT ADAPTER .................... 3-24 DOOR-OPEN LOCK ..........................3-25 SASH GLASS INTERMEDIATE LOCK..................... 3-25 CAP, COVER WITH LOCK........................3-26 HOT AND COOL BOX ..........................3-27 OPERATION MANUAL STORAGE ......................3-27 ASHTRAY ..............................
Page 13 FOREWORD CONTENTS TROUBLESHOOTING............................3-102 AFTER RUNNING OUT OF FUEL......................3-102 TOWING THE MACHINE ........................3-102 IF BATTERY IS DISCHARGED......................3-103 OTHER TROUBLE ..........................3-107 MAINTENANCE GUIDE TO MAINTENANCE ..........................4-2 OUTLINE OF SERVICE............................4-5 OUTLINE OF OIL, FUEL, COOLANT ......................4-5 RELATING TO ELECTRIC SYSTEM ......................
Page 14 FOREWORD CONTENTS ATTACHMENTS, OPTIONS GENERAL PRECAUTIONS ..........................6-2 PRECAUTIONS RELATED TO SAFETY ....................6-2 HANDLING HYDRAULIC RIPPER........................6-3 GENERAL VIEW............................6-3 EXPLANATION OF COMPONENTS ......................6-4 OPERATION............................... 6-5 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE ............6-5 ADJUSTMENT OF WORK EQUIPMENT ....................6-5 TROUBLESHOOTING..........................
Page 15 FOREWORD CONTENTS MEMO 1-14...
Page 16: Safety
SAFETY WARNING Please be sure that you fully understand this manual and the precautions related to safety for the machine. When operat- ing or servicing the machine, always follow these precaus- tions strictly.
Page 17 SAFETY SAFETY SAFETY SAFETY LABELS..............................2-4 POSITIONS OF SAFETY PICTOGRAMS ....................... 2-4 SAFETY LABELS............................. 2-5 GENERAL PRECAUTIONS ..........................2-8 SAFETY RULES ............................2-8 IF ABNORMALITIES ARE FOUND ......................2-8 CLOTHING AND PERSONAL PROTECTIVE ITEMS ................2-8 FIRE EXTINGUISHER AND FIRST AID KIT ....................2-8 SAFETY FEATURES ..........................
Page 18 SAFETY SAFETY PRECAUTIONS FOR OPERATION ........................2-17 STARTING ENGINE ............................2-17 CHECKS BEFORE STARTING ENGINE ....................2-17 PRECAUTIONS WHEN STARTING......................2-18 PRECAUTIONS IN COLD AREAS ......................2-18 OPERATION..............................2-19 CHECKS AFTER OPERATION ........................ 2-19 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE ..........2-19 PRECAUTIONS WHEN TRAVELING.......................
Page 19: 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. POSITIONS OF SAFETY PICTOGRAMS...
Page 20: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Precautions for operation, inspection and mainte- (2) Precautions when traveling in reverse nance (09651-03001) (09802-13000) (3) Precautions for leaving the operator's seat (4) Precautions for high-temperature hydraulic oil (09654-33001) (09653-03001)
Page 21 SAFETY SAFETY LABELS (5) Precautions for high-temperature cooling water (6) Precautions for check and adjust track tension (09668-03001) (09657-03003) Safety label is attached on the back side of the inspection cover of the track frame. (7) Precautions for handling electric wires (8) Warning for battery (09664-30082) (09808-03000)
Page 22 SAFETY SAFETY LABELS (9) Caution for engine running (09667-03001) (10) Caution for approach when machine moving (09812-13000)
Page 23: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. 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 24: Safety Features
SAFETY GENERAL PRECAUTIONS SAFETY FEATURES Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition. KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation.
Page 25: Handrails And Steps
SAFETY GENERAL PRECAUTIONS When leaving the machine, always lower the work equip- ment completely to the ground, set safety lock lever(1) and brake lock lever(2) securely to the LOCK position, then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place.
Page 26: Mounting And Dismounting
SAFETY GENERAL PRECAUTIONS For power tiltdozer To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe) to ensure that you support yourself. Do not grip the control levers when getting on or off the machine.
Page 27: Prevention Of Burns
SAFETY GENERAL PRECAUTIONS PREVENTION OF BURNS Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radi- ator cap by hand before starting the operation.
Page 28: Action If Fire Occurs
Komatsu distributor. If ROPS is deformed by falling objects or by rolling over, its strength lowers and its design functions cannot be maintained. In this case, be sure to ask your Komatsu distributor about repair method. 2-13...
Page 29: Precautions For Attachments
Any modification mode without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications made without authorization from Komatsu. SAFETY AT WORKSITE Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Page 30: Working On Loose Ground
SAFETY GENERAL PRECAUTIONS WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over.
Page 31: Ventilation For Enclosed Areas
Do not allow other persons to approach during the operation. 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. 2-16...
Page 32: 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 (1). CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.
Page 33: Precautions When Starting
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN STARTING When starting the engine, sound the horn as a warning. Start and operate the machine only while seated. Do not allow anyone apart from the operator to ride on the machine. Do not short circuit the starting motor circuit to start the engine. It is not only dangerous, but will also cause damage to the equipment.
Page 34: Operation
SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS AFTER 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. Always fasten your seat belt. Check the actuating condition of the work equipment, travel, and brake systems.
Page 35: Precautions When Traveling
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING When traveling on flat ground, keep its height at 40 to 50cm (16 to 20in) above the ground. When traveling on rough ground, travel at low speed and do not operate the steering suddenly. There is danger that the machine may turn over.
Page 36: Traveling On Slopes
SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. When traveling on slops, keep the blade approxmately 20 to 30cm (8 to 12in) above the ground. In case of emer- gency, quickly lower the blade to the ground to help the machine to stop.
Page 37: Parking Machine
SAFETY PRECAUTIONS FOR OPERATION PARKING MACHINE Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground. When leaving the machine, set the steering, directional and gear shift levers in the N(Neutral) position and set the blade lever in the holding position, then apply safety lock...
Page 38: Transportation
SAFETY PRECAUTIONS FOR OPERATION TRANSPORTATION 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. Always do as follows. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of the road or cliff.
Page 39: 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. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 40: 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. 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 41: Towing
If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic system, the brake works and the machine cannot move. To move the machine in this case, the oil pressure in the brake circuit must be heightened to the specified level with a special device. Ask your Komatsu distributor. 2-26...
Page 42: Precautions For Maintenence
SAFETY PRECAUTIONS FOR MAINTENENCE PRECAUTIONS FOR MAINTENANCE WARNING TAG 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 43: Stop Engine Before Carrying Out Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENENCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Stop the machine on firm, level ground. Select a place where there is no danger of falling rocks, landslides, or flooding. Lower the work equipment completely to the ground and stop the engine.
Page 44: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENENCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows.
Page 45: Attachments
SAFETY PRECAUTIONS FOR MAINTENENCE ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall. And take steps to prevent unauthorized persons from entering the storage area.
Page 46: Repair Welding
SAFETY PRECAUTIONS FOR MAINTENENCE REPAIR WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with a proper equip- ment. There is a hazard of fire or electrocution when carrying out welding, so never allow any unqualified person- nel to carry out welding.
Page 47: Precaution With High-Pressure Oil
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 48: Precautions For Maintenence
SAFETY PRECAUTIONS FOR MAINTENENCE MAINTENANCE FOR AIR CONDITIONER If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frost- bite. Never touch refrigerant. COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious injury or property damage caused by flying particles.
Page 49 SAFETY PRECAUTIONS FOR MAINTENENCE MEMO 2-34...
Page 50: Operation
OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section.
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 Radiator mask Lift cylinder (10) Idler Track shoe (11) Frame Sprocket (12) Canopy...
Page 52: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Machine equipped with cab Fuel control lever (14) Safety lock lever (for blade control lever) Cigarette lighter (15) Brake lock lever Steering, directional and gear shift lever (16) Service meter Air conditioner panel or heater panel (17) Engine water temperature gauge Head lamp switch (18) Transmission oil temperature gauge...
Page 53 OPERATION GENERAL VIEW Machine equipped with canopy Fuel control lever (13) Brake lock lever Steering, directional and gear shift lever (14) Service meter Head lamp switch (15) Engine water temperature gauge Rear lamp switch (16) Transmission oil temperature gauge Glow switch (17) Fuel gauge Speed range display lamp (18) Transmission oil temperature caution lamp...
Page 54: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the meanings of the displays. MONITOR PANEL Service meter Engine oil pressure caution lamp...
Page 55 OPERATION EXPLANATION OF COMPONENTS ENGINE WATER TEMPEARTURE GAUGE This gauge(2) indicates the cooling water temperature. When the indicator is in the white range during operation, the water temperature is normal. If the indicator moves from the white range into the red range during operation, stop the machine immediately, run the engine under no load at a midrange speed, and wait for the indicator to go down to the white range.
Page 56 OPERATION EXPLANATION OF COMPONENTS CHARGE LAMP This lamp(6) indicates malfunction of the alternator. When the starting switch is turned ON, it will light up, but it should go out when the engine speed rises. If the lamp lights up during operation, stop the engine and check the V-belt tension.
Page 57 OPERATION EXPLANATION OF COMPONENTS MONITOR CAUTION LAMP This lamp(10) lights up when any of the following caution lamps lights up. In addition, the alarm buzzer sounds at the same time. Engine water temperature caution lamp Charge lamp Engine oil pressure caution lamp Transmission oil temperature caution lamp MONITOR CAUTION CANCAL SWITCH This switch(11) is used to cancel monitor caution lamp.
Page 58: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Machine equipped with cab Machine equipped with canopy Head lamp switch Cigarette lighter (machine equipped with cab) Rear lamp switch Room lamp (machine equipped with cab) Glow switch Wiper switch (machine equipped with cab) Starting switch Additional working lamp switch Horn switch (machine equipped with cab) (if equipped)
Page 59 OPERATION EXPLANATION OF COMPONENTS HEAD LAMP SWITCH This switch(1) lights up the head lamps. OFF position: Lamps are out ON position: Lamps light up REAR LAMP SWITCH This switch(2) lights up the rear lamps. OFF position: Lamps are out ON position: Lamps light up GLOW SWITCH This switch(3) actuates the electrical heater to warm up the engine intake air.
Page 60 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch(4) is used to start the engine. 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. ON position: In this position, electric current flows in the charging and lamp circuits.
Page 61 OPERATION EXPLANATION OF COMPONENTS ROOM LAMP SWITCH (Machine equipped with cab) This lamp is used to turn on and off room lamp(7). ON position: Lamp lights up OFF position: Lamp is out WIPER SWITCH (Machine equipped with cab) This switch(8) activates the wipers. The wiper switches are as follows.
Page 62 OPERATION EXPLANATION OF COMPONENTS Wiper and window washer If this is kept pressed to the ON position while the wiper is working, water will be sprayed out. ADDITIONAL WORK LAMP SWITCH (Machine equipped with cab) (If equipped) This switch(9) is used to turn on the additional working lamp. (A)Head lamp switch (B)Rear lamp switch Push in the direction of the arrow to turn on the lamps.
Page 63: Lamp
OPERATION EXPLANATION OF COMPONENTS LAMP Machine equipped with cab. Following illustration shows machine equipped with air conditioner. Machine equipped with canopy (1)Speed range display lamp SPEED RANGE DISPLAY LAMP This lamp(1) indicates the currently selected gear speed range. When lamp 1 lights up: 1st When lamp 2 lights up: 2nd When lamp 3 lights up: 3rd 3-14...
Page 64: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Fuel control lever (5)Brake lock lever Steering, directional and gear shift lever (6)Safety lock lever (for blade control lever) Brake pedal (7)Blade control lever Decelerator pedal FUEL CONTROL LEVER This lever(1) is used to control the engine speed and output. (a)Low idling position: Push the lever forward fully.
Page 65 OPERATION EXPLANATION OF COMPONENTS STEERING, DIRECTIONAL AND GEAR SHIFT LEVER This lever(2) is used to select the direction of travel, to carry out steering, and to carry out counterrotation turns. Forward-reverse shifting Position (a): FORWARD Position (b): REVERSE Position N: NEUTRAL Steering Position (c): LEFT TURN Position (d): RIGHT TURN...
Page 66 OPERATION EXPLANATION OF COMPONENTS As the gear is shifted, one of the gear speed lamps on the front panel lights up. 1st: Lamp 1 lights up. 2nd: Lamp 2 lights up. 3rd: Lamp 3 lights up. Counterrotation turn WARNING 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 coditions and be careful not to hit any obsta- cles.
Page 67 OPERATION EXPLANATION OF COMPONENTS DECELERATION PEDAL WARNING Do not place your foot on this pedal unnecessarily. 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. To prevent this, depress the decelerator pedal to reduce the travel speed.
Page 68 OPERATION EXPLANATION OF COMPONENTS SAFETY LEVER (FOR BLADE CONTROL LEVER) WARNING When standing up from the operator’s seat, always set the safety lever securely to the LOCK position. If the blade control and ripper control levers are not locked and are touched by accident, it may lead to serious injury or damage.
Page 69 OPERATION EXPLANATION OF COMPONENTS Tilting control (e)LEFT TILT (f)RIGHT TILT Tilting distance of power angle, power tiltdozer Tilting distance Condition STD blade Wide blade of blade D61PX D61EX D61EX 600mm 510mm 600mm Right tilt (23.6in) (20.1in) (23.6in) 600mm 510mm 600mm Left tilt (23.6in) (20.1in)
Page 70 OPERATION EXPLANATION OF COMPONENTS POWER TILTDOZER This lever(7) is used to lift or tilt the blade. Lifting control (a)RAISE: (b)HOLD: Blade is stopped and held in this position. (c)LOWER: (d)FLOAT: Blade will move freely according to external force. REMARK When released from FLOAT position, this lever will not return to HOLD position, so it must be moved back by hand.
Page 71: Fuse
OPERATION EXPLANATION OF COMPONENTS FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. 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 72 OPERATION EXPLANATION OF COMPONENTS Fuse box(2) Fuse capacity Name of circuit Cab radio, Back-up power source (Spare) Air conditioner Electric power take-out Chassis power source Fuse box(3) (Machine equipped with cab) Fuse capacity Name of circuit Radio memory Radio, lamps, cigarette lighter Rear wiper Right door wiper Front wiper...
Page 73: Electric Power Take-Out Adapter
OPERATION EXPLANATION OF COMPONENTS ELECTRIC POWER TAKE-OUT ADAPTER NOTICE Do not use as a power supply for 12V equipment. This will cause failure of the equipment. When using as a power supply pickup, do not install equipment which exceeds 120W (24V x 5A). (Machine equipped with cab) It is possible to remove the cigarette lighter and use the socket as a power supply.
Page 74: Door-Open Lock
OPERATION EXPLANATION OF COMPONENTS DOOR-OPEN LOCK (Machine equipped with cab) Use this when your want to keep the door held open. Push the door against the door catch(1). The door will be held by the door catch. To release the door, move lever(2) inside the cab to the front of the cab.
Page 75: Cap, Cover With Lock
OPERATION EXPLANATION OF COMPONENTS CAP, COVER WITH LOCK The fuel tank cap, hydraulic tank cap, cab door opener, front top cover of the machine, battery check cover, both engine side covers, drain valve of the fuel tank, and inspection cover are equipped with locks.
Page 76: Hot And Cool Box
OPERATION EXPLANATION OF COMPONENTS HOT AND COOL BOX (Machine equipped with cab) This is at the top of the front panel. It can be used to warm or cool three canned drinks. This is interconnected with the air conditioner: During heating, it warms up the drinks;...
Page 77: Ashtray
OPERATION EXPLANATION OF COMPONENTS ASHTRAY (Machine equipped with cab) 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 78: Air Conditioner
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER (Machine equipped with cab, air conditioner) EXPLANATION OF PARTS Fresh/recirc selector lever Blower switch Air condition switch Temperature control lever FRESH/RECIRC SELECTOR LEVER This lever(1) changes the air intake port used when cooling or heating.
Page 79 OPERATION EXPLANATION OF COMPONENTS BLOWER SWITCH This switch(3) acts as the wind flow control switch and main switch when cooling or heating. The air flow can be set to three stages: 1(LOW) → 2(MEDIUM) → 3(HIGH). If the switch is set to 0, the power is switched off and the air conditioner stops.
Page 80 OPERATION EXPLANATION OF COMPONENTS COOLING OPERATION When the cooling operation is carried out, the inside of the cab is cooled, and at the same time the drinks inside the hot and cool box can be cooled. COOLING (RECIRC) When the control switch and lever are operated as shown in the diagram, a cool breeze is sent out.
Page 81 OPERATION EXPLANATION OF COMPONENTS HEATING OPERATION When the heating operation is carried out, the inside of the cab is heated, and at the same time the drinks inside the hot and cool box can be heated. HEATING (RECIRC) When the control switch and lever are operated as shown in the diagram, warm air is sent out.
Page 82 OPERATION EXPLANATION OF COMPONENTS PREVENTION METHOD OF ENTRY OF DUST Entry of dust into the cab can be prevented by starting the blower fan for the air conditioner to raise the pressure in the cab a little higher than outside. When working in a dusty job site or when preventing dust from entering the cab, use this function.
Page 83 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR REPLACING RECEIVER Replace the receiver once every two years. After replacing the receiver, add compressor oil. Turn the receiver at an angle and measure the oil remaining inside the receiver, then add the same amount of oil (Denso Oil 6) to fill the receiver. REMARK Depending on the condition of use, the replacement interval may be shorter.
Page 84: Heater
OPERATION EXPLANATION OF COMPONENTS HEATER (Machine equipped with cab, heater) EXPLANATION OF PARTS FRESH/RECIRC selector lever Temperature control lever Blower switch FRESH/RECIRC SELECTOR LEVER This lever(1) changes the air intake port used when cooling or heating. RECIRC: If lever(1) is shifted to the left, the air conditioner sucks inside air.
Page 85 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL LEVER This lever(3) is used to control the temperature for heating. When the temperature control lever is moved to the right, the temperature of the air coming from the vents becomes lower. When the temperature control lever is moved to the left, the temperature of the air coming from the vents becomes higher.
Page 86 OPERATION EXPLANATION OF COMPONENTS CREANING AIR FILTER If the air filter for the FRESH or RECIRC air intake becomes clogged, the heating capacity will drop. In places where there is a lot of dust, clean the air with compressed air once a week. For details of the cleaning method, see "CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (PAGE 4-48)".
Page 87: Operation
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Do not get on or off the machine from the rear. Using this position is dangerous because it is easy to slip and you cannot be seen from the operator's compartment.
Page 88 OPERATION OPERATION Check for damage to gauges, lamps on instrument panel, loose bolts Check that there is no damage to the panel, gauges and lamps. If any abnormality is found, replace the parts. Clean off any dirt on the surface. Check for damage to seat belt and mounting clamps Check that there is no abnormality in the seat belt or mounting clamps.
Page 89 OPERATION OPERATION CHECK BEFORE STARTING Always carry out the items of the checks in this section before starting the engine. CHECK COOLANT LEVEL, ADD WATER WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank.
Page 90 1 second. REMARK If the lamps do not light up, there may be a failure or dis- connection in the monitor, so please contact your Komatsu distributor. When carrying out the checks before starting, do not relay only on the monitor.
Page 91 If any lamp does not light up or two or more lamps light up, or if the lighting lamp does not change even the gear is shifted, the gear speed lamp system or its wire may be broken. In this case, call your Komatsu distributor and ask for inspection. 3-42...
Page 92 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When supplying fuel, take care not to spill it. It can catch fire. Wipe off any spilt fuel. If fuel has spilt over soil or sand, remove that soil or sand together. Fuel is highly flammable and dangerous.
Page 93 OPERATION OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, 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. Open the engine side cover on the left side of the chas- sis.
Page 94 Depress the brake pedal all the way until it stops. The distance of travel at the center of the pedal should be 70 to 90mm (2.8 to 3.5in). When this value exceeds 91mm (3.6in), or the brake fails to work, please contact your Komatsu distributor for adjustment. 3-45...
Page 95 ON position and check that the head lamps and rear lamps light up. If the lamps do not light up, there is probably a broken bulb or disconnection in the wiring, so contact your Komatsu distributor for repairs. 3-46...
Page 96 OPERATION OPERATION DOES THE HORN SOUND NORMALLY? Insert the key into starting switch and turn the key to the ON position. Push the horn switch and check that the horn sounds. CHECK BACK-UP ALARM SOUND Insert the key into starting switch and turn the key to the ON position.
Page 97 OPERATION OPERATION CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER (If equipped) The water separator separates water mixed in the fuel. If float (2) is at or above red line (1) , drain the water according to the following procedure.
Page 98 OPERATION OPERATION ADJUSTMENT ADJUST OPERATOR'S SEAT WARNING Adjust the seat position at the beginning of each shift or when operators change. Adjust the seat so that the brake pedal can be depressed all the way with the operator’s back against the backrest.
Page 99 OPERATION OPERATION ADJUST ARM REST The height of the armrests on both sides of the operator's seat can be adjusted to three levels. After adjusting the operator's seat, adjust the height of the armrests properly. Loosen knobs(1) on both sides of the operator's seat. Move the armrests on both sides of the operator's seat forward, then adjust their height to (H), (M), or (L).
Page 100 OPERATION OPERATION USING SEAT BELT Always install a seat belt on machines equipped with ROPS. WARNING Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting belt of the belt. If the belt is worn or damaged, replace it. Replace the seat belt every three years, even if their outside is free from abnormality.
Page 101 OPERATION OPERATION OPERATION AND CHECK BEFORE STARTING ENGINE WARNING If the work equipment control levers are touched by acci- dent, the work equipment may move suddenly. When leav- ing the operator's compartment, always set the safety lever securely to the LOCK position. Check that the brake pedal is locked with brake lock lever(1).
Page 102 OPERATION OPERATION Check that speed range display lamp(2) shows 1st. Check that steerling, directional and gear shift lever(3) is at the N (neutral) position. Check that the blade is lowered to the ground and that blade control lever(4) is at the HOLD position. Check that the safety lock lever(5) is locked.
Page 103: Starting Engine
OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Never use starting aid fluids as they may cause explo- sions. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 104 OPERATION OPERATION When the engine starts, release the key in starting switch(2). The key will return automatically to the ON position. STARTING IN COLD WEATHER When starting in low temperatures, do as follows. WARNING Never use starting aid fluids as they may cause explo- sions.
Page 105 OPERATION OPERATION Pull fuel control lever(1) to a position midway between the low idling and full speed positions. Insert the key into starting switch(2) and turn the key to the ON position. Carry out preheating. There are the following two ways of carrying out preheating. First use the convenient automatic preheating system.
Page 106 OPERATION OPERATION AUTOMATIC PREHEATING Turn glow switch(3) to the AUTO position. When it is turned to the AUTO position, preheating is automatically carried out according to the ambient tem- perature. Lamp(4) lights up during the preheating opera- tion. When the preheating is completed, lamp(4) will go out.
Page 107 OPERATION OPERATION MANUAL PREHEATING Turn glow switch(3) to position I or II. Lamp(4) lights up during the preheating operation. When the preheating is completed, release the switch. The key will then return automatically to the following position. From position I, it will return to AUTO From position II, it will return to OFF The preheating times are as shown below.
Page 108: Operations And Checks After Starting Engine
After starting the engine, do not immediately start operations. First, carry out the following operations and checks. 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 109 OPERATION OPERATION Pull fuel control lever(1) to the center position between LOW IDLING and HIGH IDLING and run the engine at medium speed for about 5 minutes with no load. After warm-up run is completed, check gauges and cau- tion lamps for proper operation. If any abnormality is found, repair it.
Page 110 OPERATION OPERATION Pull fuel control lever(1) to a position midway between the low idling and full speed positions, run the engine at a mid-range speed, and continue to run under no load for approx. 10 minutes. Operate blade control lever(3) fully to the RAISE position, then hold the lever in position, and operate slowly to the left tilt relief and right tilt relief in turn for 5 minutes.
Page 111: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradu- ally, then stop it.
Page 112: Check After Stopping Engine
OPERATION OPERATION CHECK AFTER STOPPING ENGINE Walk around the machine and check the work equipment, machine exterior, and undercarriage, and check also for leakage of oil or water. If any abnormalities are found, repair them. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard. Remove any mud affixed to the undercarriage.
Page 113: Machine Operation
OPERATION OPERATION MACHINE OPERATION MOVING MACHINE OFF WARNING When moving machine, check that the area around the machine is safe, and sound the horn before mov- ing. Clear all personnel from the machine and the area. Clear all obstacles from the path of the machine. Use extreme care when reversing the machine.
Page 114 OPERATION OPERATION Operate steering, directional and gear shift lever(4) to the desired position, and check that speed range display lamp(3) shows the correct position. Set safety lock lever(6) for blade control lever(5) to the FREE position. Put blade control lever(5) in the RAISE position to raise the blade 40 to 50mm (1.6 to 2.0in) off the ground.
Page 115 OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Depress brake pedal(1) to stop the machine. Place steering, directional and gear shift lever(2) in the N (neutral) position. 3-66...
Page 116 OPERATION OPERATION Operate steering, directional and gear shift lever(2) to 1st, and check that speed range display lamp(3) shows the correct position. 3-67...
Page 117: Shifting Gear
OPERATION OPERATION SHIFTING GEAR There is no need to stop machine to shift gears. Set steering, directional and gear shift lever(1) in the desired position to shift gear. Gear shifting Rotate the joystick 30º to carry out gear shifting operation. Position (a): 1st Position (b): 2nd Position (c): 3rd...
Page 118: Shifting Between Forward And Reverse
OPERATION OPERATION SHIFTING BETWEEN FORWARD AND REVERSE CAUTION The travel direction can be changed without stopping the machine. Do not change it while the engine is running at the full speed, however, but depress the decelerator pedal to lower the engine speed before changing the travel direction for safety, comfort, and longer life of the power train.
Page 119 For machines equipped with a backup alarm, check that the backup alarm sounds when steering, directional and gear shift lever(4) is placed in REVERSE. If the alarm does not sound, please contact your Komatsu distributor. 3-70...
Page 120: Steering Machine
OPERATION OPERATION STEERING MACHINE WARNING 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. Never make a pivot turn at high speed. NORMAL TURNING WARNING The feeling of the operation if the operator carries out a counterrotation turn when your head is facing the...
Page 121 OPERATION OPERATION TURNING TO LEFT WHILE TRAVELING FORWARD NOTICE If the lever is operated partially to the forward or reverse position and then is operated in the direction of turn, the machine may carry out a counterrotation turn, so operate the lever fully to the forward or reverse position.
Page 122 OPERATION OPERATION TURNING WHILE DESCENDING A SLOPE This machine (which can turn by counterrotation) does not cross-steer even when it descends a steep slope where it is driven down by its own weight or when it is pushed down by a towed machine on a slope. Accordingly, descend a slope as explained below.
Page 123 OPERATION OPERATION WHEN MAKING A PIVOT TURN TO THE LEFT WHILE TRAVELING If the steering, directional and gear shift lever(1) is pushed for- ward and moved fully to the left(L), the machine turns sharply to the left. (Does not become reverse steering) REMARK When making sharp turns to the right, push the steering, direc- tional and gear shift lever(1) forward, and move it fully to the...
Page 124: Precautions For Operation
OPERATION OPERATION PRECAUTIONS FOR OPERATION PERMISSIBLE WATER DEPTH When operating in water, always keep the bottom of carrier roller(1) above the surface of the water. Also, be careful that the engine cooling fan will not come in contact with water. The fan can be damaged.
Page 125 OPERATION OPERATION IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT OBSTRUCT THE VIEW (Machine equipped with cab) For safety reasons, do not install anything to the cab glass that will obstruct the view. Always keep the glass clean to ensure safety during operations. PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY WARNING The cab stay cause blind spots.
Page 126: 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 127 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 up root trees or stumps or fell trees by angling or tilting the blade.
Page 128: Adjusting Posture Of Work Equipment
OPERATION OPERATION ADJUSTING 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 apply the locks securely to the safety lock lever.
Page 129 OPERATION OPERATION ADJUST AMOUNT OF TILTPOWER 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 safety lock lever.
Page 130: Parking Machine
OPERATION OPERATION PARKING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. 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 lever in the LOCK position and insert blocks underneath the track shoes.
Page 131 OPERATION OPERATION Place steering, directional and gear shift lever(2) in the N (neutral) position. Operate joystick(2) to 1st, and check that speed range display lamp(3) shows the correct position. Operate brake lock lever(4) to lock the brakes. Operate blade control lever(5) to the LOWER position, and lower the blade to the ground.
Page 132: Check After Finishing Work
OPERATION OPERATION CHECK AFTER FINISHING WORK Use the meters and caution lamps to check the engine water temperature, engine oil pressure, fuel level, and transmission oil temperature. LOCKING To prevent vandalism, there are locks at the following places. Places that can be locked with the starting switch key. Top cover at front of chassis(1) Right and left engine side cover(2) Battery inspection cover(3)
Page 133: Tips For Longer Undercarriage Life
OPERATION METHOD 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. Do not allow shoe slipping to occur during operation. If shoe slipping occurs, reduce load to the blade until slipping stops.
Page 134 OPERATION OPERATION INSPECTION AND ADJUSTMENT Properly adjust track tension. Check the track tension by measuring clearance A between the idler and carrier roller shown in the figure at right. Clearance A should be 20 to 30mm (0.8 to 1.2in) nor- mally.
Page 135 Frequent inspection and prompt repair will reduce repair costs. The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per- form periodical inspection and contact the Komatsu distributor in your area when machine has approached repair- able limits and reversing limits.
Page 136 OPERATION OPERATION MEASURING OUTSIDE DIAMETER OF TRACK ROLLER Measure height (size C) of link tread as shown. Stop machine at position where link tread, whose size C has been measured completely, contacts roller tread. Then measure size B. Calculate outside diameter of tread (size A): A = (B - C) x 2 Standard size (A): 200mm (7.9in) Repair limits: 164mm (6.5in)
Page 137: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION PROCEDURE Transport the machine on a trailer, as a rule. Select a trailer according to the mass and dimensions of the machine shown in "SPECIFICATIONS (PAGE 5-2)". Note that the mass and dimensions for transportation shown in SPECIFICATIONS depend on the types of the shoe, blade, etc.
Page 138: Removing Cab
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 139: Loading, Unloading Work
OPERATION TRANSPORTATION LOADING, UNLOADING WORK WARNING Since loading and unloading work of the machine is dangerous, take care extremely. When loading or unloading the machine, operate it slowly with the engine speed low and the trans- mission in the 1st gear. Use ramps having sufficient width, length, thickness, and strength.
Page 140 OPERATION TRANSPORTATION SECURING MACHINE WARNING When the edge of the blade protrudes beyond the trailer, angle the blade. NOTICE Be sure to retract the car radio antenna (if the machine equipped with cab). Load the machine on to a trailer as follows. Lower the work equipment slowly.
Page 141 OPERATION TRANSPORTATION Put blocks in front and behind the track shoes of both sides. Set up chain or wire, following (A) or (B). A: Set up chain or wire through the holes of track links. B: Set up chain or wire around the track shoes. Protect the wire from contacting directly with angular parts of the machine, by inserting pads.
Page 142 OPERATION TRANSPORTATION UNLOADING Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Then fix the ramps in line with the centers of the trailer and the machine.
Page 143: Lifting Machine
The lifting procedure applies to machines with standard specifications. The method of lifting differs according to the attachments and options actually installed. In such cases, please contact your Komatsu distributor for information. For details of the weight, see "SPECIFICATIONS (PAGE 5-2)".
Page 144 OPERATION TRANSPORTATION For machine equipped with ripper (For D61PX) 3-95...
Page 145 OPERATION TRANSPORTATION When lifting the machine, stop it on a level place, then observe the following procedure. Stop the engine and set the brake lock lever to the LOCK position. Install wire ropes, slings, etc. matched to the weight of the machine to the lifting points as shown in the above figure.
Page 146: Cold Weather Operation
Antifreeze is toxic. Be extremely careful when handling it. When replacing coolant containing anti- freeze or when handling coolant when repairing the radiator, contact your Komatsu distributor or ask your local antifreeze dealer. Be careful not to let the water flow into drainage ditches or spray on to the ground surface.
Page 147 OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas, so do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.
Page 148: After Completion Of Work
OPERATION COLD WEATHER OPERATION AFTER COMPLETION OF WORK WARNING Performing idle-running of the tracks is dangerous, so stay well away from the tracks. After completion of operations, fill the fuel tank to prevent the formation of water caused by conden- sation of moisture in the empty space in the tank when the temperature goes down.
Page 149: Long-Term Storage
NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. When using the machine after long-term storage, do as follows before using it. Wipe off the grease from the hydraulic cylinder rods.
Page 150: Starting Machine After Long-Term Storage
OPERATION LONG-TERM STORAGE STARTING MACHINE AFTER LONG-TERM STORAGE When starting the engine after long-term storage, cancel the automatic warming-up operation as follows. Turn the starting switch key to the ON position. Pull the fuel control lever from the LOW idling position to the FULL position, and hold it there for at least 3 seconds, then return it to the LOW idling position and start the engine.
Page 151: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before starting. For details of bleeding the air, see "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-49)". TOWING THE MACHINE WARNING Be sure to use a wire rope sufficiently strong for the towing weight.
Page 152: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a haz- ard of explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks.
Page 153 OPERATION TROUBLESHOOTING REMOVE AND INSTALL BATTERY Open battery cover(1), remove 4 bolts(2) on the inside, then remove cover(1). Before removing battery, remove the ground cable (nor- mally connected to the negetive (-) terminal). If any tool touches between the positive terminal and the chassis, there is danger of sparks being generated.
Page 154 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING When connecting the cables, never contact the posi- tive(-) and negative(+) terminals. When starting the engine with a booster cable, always wear safety glasses and rubber gloves.
Page 155 OPERATION TROUBLESHOOTING STARTING ENGINE CAUTION Always check that the safety lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are at the HOLD or neutral position. Make sure the clips are firmly connected to the battery terminals.
Page 156: Other Trouble
OPERATION TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 157 OPERATION TROUBLESHOOTING CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problam Main causes Remedy When brake pedal is depress,...
Page 158 OPERATION TROUBLESHOOTING ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pan oil level is low...
Page 159 OPERATION TROUBLESHOOTING Problem Main causes Remedy Low grade fuel being used Change to specified fuel Overheating See item "Indicator of water tem- Abnormal noise generated perature gauge is in red range (combustion or mechanical) on right side of gauge" Damage inside muffler Replace muffler) Excessive valve clearance Adjust valve clearance)
Page 160: Maintenance
MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 161: Guide To Maintenance
KOMATSU GENUINE REPLACEMENTPARTS: 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 windshield washer fluid, and be sure not to let any dirt get into it.
Page 162 MAINTENANCE GUIDE TO MAINTENANCE DO NOT DROP THINGS INSIDE MACHINE: When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop nuts, bolts, or tools inside the machine. If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will lead to failure.
Page 163 MAINTENANCE GUIDE TO MAINTENANCE LOOKING THE INSPECTION COVERS: When carrying out maintenance with the inspection cover open, lock it in position securely with a lock bar. If inspection or maintenance is carried out with the inspection cover open and not locked in position, there is a haz- ard that it may be suddenly blown shut by the wind and cause injury to the worker.
Page 164: Outline Of Service
When changing the oil, always replace the related filters at the same time. We recommend you to 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 The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Page 165 When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
Page 166: Relating To Electric System
Service relating to the electric system is check of fan belt tension, check of damage or wear in the fan belt and check of battery fluid level. Never install any electric components other than there specified by Komatsu. External electrical interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your Komatsu distributor.
Page 167 MAINTENANCE OUTLINE OF SERVICE Inspection and maintenance includes inspection of the hydraulic oil level, replacement of filters, and changing the hydraulic oil. When removing high-pressure hoses, check that there is no damage to the O-ring. If any damage is found, replace.
Page 168: Wear Parts
The wear parts should be changed correctly in order to use the machine economically. When changing parts,use Komatsu genuine parts of excellent quality. When ordering parts, please check the part number in the parts book.
Page 169: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
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 Cooling Engine Damper Idler Hydraulic Power train Final drive Fuel system...
Page 170 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil than matches the temparature in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydrauric work equipment applications.
Page 171 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 172 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 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.) FINA potonic N...
Page 173: Standard Tightening Torques For Bolts And Nuts
The tightening torque is determined by the width across the flats of the nut and bolt. 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 174: Periodic Replacement Of Safety Critical Parts
These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. With these parts, the material changes as time passes, or they easily wear out or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition.
Page 175: Safety Critical Parts
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q'ty Replacement interval Fuel hose (fuel tank - injection pump) Fuel hose (injection pump - fuel filter) Feul return hose (injection pump - fuel tank) Fuel return hose (injection nozzle - fuel tank) Hose (PPC charge valve - PPC valve) Hose (hydraulic tank - PPC valve)
Page 176: Maintenance Schedure Chart
MAINTENANCE MAINTENANCE SCHEDURE CHART MAINTENANCE SCHEDURE CHART MAINTENANCE SCHEDURE CHART WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ................4-19 CLEAN INSIDE OF COOLING SYSTEM......................4-23 CHECK TRACK TENSION ..........................4-25 CHECK AND TIGHTEN TRACK SHOE BOLTS ....................4-26 CHECK ELECTRICAL INTAKE AIR HEATER ....................
Page 177 MAINTENANCE MAINTENANCE SCHEDURE CHART EVERY 250 HOURS SERVICE LUBRICATING ..............................4-42 GREASE EQUALIZER BAR SIDE PIN ....................... 4-43 GREASE EQUALIZER BAR CENTER PIN......................4-43 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..................4-44 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..................4-44 CHECK LEVEL OF BATTERY ELECTROLYTE ....................
Page 178: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and the engine will suffer damage. Always stop the engine before carrying out these opera- tions.
Page 179 MAINTENANCE SERVICE PROCEDURE CLEANING OR REPLACING OUTER ELEMENT Open the left engine side cover. Remove four clips(2) to remove dust cup(3). NOTICE Never remove inner element (5). If it is removed, dust will enter and cause an engine trouble. Remove outer element(4). NOTICE When cleaning the dust cup, do not remove evacuator valve(6).
Page 180 MAINTENANCE SERVICE PROCEDURE If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE When cleaning the element, do not hit or beat it against anything.
Page 181 MAINTENANCE SERVICE PROCEDURE NOTICE When cleaning the dust cup, do not remove evacuator valve(6). Clean the inside of the air cleaner body and dust cup. Remove inner element(5), then install a new inner element immediately. Set new outer element(4) and install dust cup(3), then secure them with clips(2). CAUTION When installing the dust cup, check O-ring(7).
Page 182: Clean Inside Of Cooling System
MAINTENANCE SERVICE PROCEDURE CLEAN INSIDE OF COOLING SYSTEM WARNING Just after the engine is stopped, the cooling water 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 lowers, then loosen the cap slowly to release the pressure.
Page 183 If it gets in your eyes, flush your eyes with large quantities of fresh water and see a doctor at once. Use city water for the cooling water. 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 184: Check Track Tension
If the track tension is not relieved by this procedure, please contact your Komatsu distributor. WHEN INCREASING TENSION Prepare a grease gun. Pump in grease through the grease fitting with a grease pump.
Page 185: Check And Tighten Track Shoe Bolts
WARNING It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. Loosen lubricator(1) gradually to release the grease. Turn lubricator(1) a maximum of one turn.
Page 186: Check Electrical Intake Air Heater
After checking the link contact surfaces, tighten the bolt by 180º (Allowable range: 0º - 20º). 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 187: Reverse And Replace The End Bits And Cutting Edges
MAINTENANCE SERVICE PROCEDURE REVERSE AND REPLACE THE END BITS AND CUTTING EDGES WARNING It is dangerous if the work equipment moves by mistake when the cutting edges and end bits are being reversed or replaced. Set the work equipment in a stable condition, then stop the engine and lock the blade control lever securely with the safety lock lever.
Page 188: Clean, Check Rediator Fins
MAINTENANCE SERVICE PROCEDURE REMARK If the cutting edge and the end bit on both sides are worn out, replace with new one. If it has been worn out up to the fitting surface, repair the fitting surface and then reverse or replace. Remove the cutting edge and the end bit and clean the mounting surface.
Page 189: Adjust Idler Clearance
MAINTENANCE SERVICE PROCEDURE ADJUST IDLER CLEARANCE Since the idlers are forced to move forward and backward by an external force guide plates will be worn out. Wear of these plates will cause the vibration of idlers from side to side or inclination of the idlers, and running off of track links from the idlers or unevenly worn idler and links may result.
Page 190: Adjusting Tension Of Center Brace
MAINTENANCE SERVICE PROCEDURE ADJUSTING TENSION OF CENTER BRACE (Power tiltdozer only) When the blade assembly is removed for transportation, the tension of the center brace must be adjusted when the blade is assembled again. If the tension is not adjusted, the bushing at the blade and straight frame mount will come out, and soil will enter.
Page 191: Check, Inspection Air Conditioner (Mechine Equipped With Cab)
MAINTENANCE SERVICE PROCEDURE CHECK, INSPECTION AIR CONDITIONER (Machine equipped with cab) CHECKING TENSION OF COMPRESSOR BELT If the belt is loose, it will slip and the cooling effect will be reduced. From time to time, press a point midway between the drive pulley and compressor pulley with your finger (approx.
Page 192: Grease Door Hinge (Mechine Equipped With Cab)
MAINTENANCE SERVICE PROCEDURE OPERATING THE AIR CONDITIONER OFF-SEASON Even during the off-season, run the compressor at low speed for 3 to 5 minutes once a month to prevent the loss of the oil film at the lubricated parts of the compressor. GREASE DOOR HINGE (Machine equipped with cab) If the door makes a squeaking noise when it is opened or...
Page 193: Check Window Washer Fluid Level, Add Fluid (Mechine Equipped With Cab)
MAINTENANCE SERVICE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab) If there is air in the window washer fluid, check the level and add fluid. Open the engine side cover on the left side, check the level of the fluid in window washer tank(1), and if it is low, add automo- bile window washer fluid.
Page 194: Replace Wiper Blade (Mechine Equipped With Cab)
MAINTENANCE SERVICE PROCEDURE REPLACE WIPER BLADE (Machine equipped with cab) If the blade is damaged, it will not wipe the window clean, so replace the blade. REPLACEMENT FRONT, REAR WIPER Remove screw(1), then remove the blade. Install a new blade, then tighten screw(1) securely. DOOR WIPER It is hooked at portion (A), so move the blade in the direc- tion of the arrow to remove it.
Page 195: Check Idler Oil Level, Add Oil
If the oil level in the idler is low, new oil must be added, and the machine body must be inclined in this case. Since this work is dangerous, ask your Komatsu distributor. If the oil level in the idler is low, noise will be generated and there will be seizure, so check the oil level and add oil as follows.
Page 196: Check Oil Level In Damper Case, Add And Change Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN DAMPER CASE, ADD AND CHANGE OIL WARNING The oil is very hot just after the operation. Wait until the oil temperature drops, then start the work. The undercover is heavy. Do not open or close it just under it.
Page 197: Procedure For Bleeding Air Of Hydraulic System
MAINTENANCE SERVICE PROCEDURE REPLACEMENT Container of 4 liters or larger to receive drained oil Quantity of replacement oil: 1.3 liters (0.34 US gal) Remove oil level plug(3) and oil filler plug(4), then remove drain plug 5 to drain the oil. After the all oil is drained, tighten plug(5).
Page 198: Procedure For Releasing Internal Pressure Of Hydraulic System
MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM WARNING The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or hoses, always release the pressure in the circuit before starting. If the pressure is not released, high pressure oil may spurt out and cause serious personal injury.
Page 199: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-40)" in the OPERATION section. Check coolant level, add water Checking with machine monitor Check speed range display lamp Check fuel level, add fuel Check oil level in engine oil pan, add oil Check oil level in power train case, add oil Check brake pedal travel...
Page 200: Every 50 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE DRAIN WATER, SEDIMENT FROM FUEL TANK Drain water and sediment before starting the machine. Prepare a container to receive fuel to be drained. Open drain valve(1) at the bottom of the tank to drain sediment and water accumulated on the bottom, together with fuel.
Page 201: 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 Lower the blde to the ground, then stop the engine. Using a grease pump, pump in grease through the grease fittings shown by arrows. After greasing, wipe off any old grease that was pushed out.
Page 202: Grease Equalizer Bar Side Pin
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) GREASE EQUALIZER BAR SIDE PIN One place on each side of machine body...
Page 203: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. Remove oil level plug(1) and check whether the final drive case is filled with oil to lower edge of the plug hole.
Page 204: Check Level Of Battery Electrolyte
MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE WARNING Since the battery produces combustible gas and can explode, do not bring fire near it. Battery fluid is a dangerous substance. Take care that it does not get in your eyes or on skin. If it does, wash it away with a large quantity of water, then see a doctor.
Page 205: Check Fan Belt Tension, Adjust
V-belt is not touching the bottom of the V-groove. If any pulley is defective, ask your Komatsu distributor to replace it. If any belt has stretched and there is no allowance for adjustment, or if there are cuts or cracks on any belt, replace both belts at the same time.
Page 206: Check, Clean Fuel Strainer
After installing, open the fuel supply valve. 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 207: Clean Air Conditioner Air Filter (Fresh/Recirc Filter) (Mechine Equipped With Cab)
MAINTENANCE SERVICE PROCEDURE Depress brake pedal(4) and move steering, directional and gear shift lever(5) in 2nd. Operate fuel control lever(6) to raise the engine speed gradually to full throttle. Check that the machine does not move. This indicates that brake performance is normal. CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (Machine equipped with cab) Clean the air conditioner air filter if it becomes clogged or if there is dirt or oil stuck to it.
Page 208: 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 Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter.
Page 209: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. Install drain valve(P). Open the engine side cover on the right side of the machine body, and remove filter cover(2) from the lower section.
Page 210: Replace Corrosion Resistor Cartridge
2/3 of a turn. Open valve (1). Use Komatsu genuine cartridge. REPLACE POWER TRAIN OIL FILTER ELEMENT Open cover at the right side of the machine. Remove mounting bolts(2) of filter(1), then remove cover(3).
Page 211: 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 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 212 MAINTENANCE SERVICE PROCEDURE Loosen mounting bolt(3) of the power train strainer, then remove cover(4). Take out spring(5), then take out strainer(6). Remove all dirt from strainer(6), then wash in clean die- sel oil or flushing oil. Clean the case interior and the removed parts.
Page 213: 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. Container to catch drained oil: Min. 27 liters capacity Refill capacity: D61EX: (each) 24 liters (6.34US gal) D61PX: (each) 27 liters (7.13US gal)
Page 214: Grease Universal Joint
MAINTENANCE SERVICE PROCEDURE GREASE 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 below the cover so that you can easily get out of the way. Apply grease to the grease fittings (2 places) shown by arrows.
Page 215: Check All Tightening Parts Of Turbocharger
Check for loose and damaged bolts. If any loose bolt is found, tighten to a torque of 927 ± 103N•m (94.5 ± 10.5kgf•m, 684 ± 76lbft) If any damaged bolt is found, replace the bolt with a genuine Komatsu bolt. 4-56...
Page 216: 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 HYDRAULIC OIL FILTER ELEMET AND CLEAN SUCTION STRAINER WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
Page 217: Clean, Check Turbocharger
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced. CHECK ALTERNATOR, STARTING MOTOR The brush may be worn or the bearing may have run out of grease, so contact your Komatsu distributor for inspec- tion or repair.
Page 218: 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. 4-59...
Page 219 MAINTENANCE SERVICE PROCEDURE MEMO 4-60...
Page 220: Specifications
SPECIFICATIONS...
Page 221 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS D61EX-12 Power angle, power tiltdozer with ROPS canopy D61PX-12 Power angle, power tiltdozer with ROPS canopy (equipped with single shoe) Item Unit D61EX-12 D61PX-12 Operating weight kg(lb) 15,800(34,839) 17,500(38,588) (without operator) Name of engine — Komatsu S6D114E-1A deisel engine...
Page 222: Attachments, Options
ATTACHMENTS, OPTIONS WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 223: 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 224: Handling Hydraulic Ripper
HANDLING HYDRAULIC RIPPER HANDLING HYDRAULIC RIPPER This ripper is for the D61EX-12. When installing it to the D61PX-12, change the track shoe to the 600 mm (23.6 in) narrow single shoe. If the ripper is installed to machines with wider track shoes, the undercarriage may be damaged.
Page 225: 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 safety lock lever to the LOCK position. This lever is used to operate the ripper.
Page 226: Operation
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER OPERATION INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE Walk-around check Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the rivets. If any abnormality is found, replace or repair. PRECAUTIONS WHEN OPERATING Travel in low speed and lower the ripper gradually when starting to move the machine off.
Page 227 ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER When changing the digging depth, do as follows. Remove cotter pin (1). Remove pin (2), change the position of the shank hole, then insert pin (2). Insert cotter pin (1). ADJUSTING DIGGING ANGLE Adjust the position of the mounting pin hole in the beam and upper link. Digging angle °...
Page 228: Troubleshooting
HANDLING HYDRAULIC RIPPER TROUBLESHOOTING OTHER TROUBLE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs.. Problem Main causes Remedy...
Page 229: Inspection And Maintenance
For details of checking the oil level in the hydraulic tank, see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL (PAGE 4-44)" SPECIFICATIONS Power angle, power tilt dozer Item Unit D61EX-12 Operating weight (not 17,120 including operator) (lb) (37,750) Weight of ripper as...
Page 230: Handling Towing Winch
HANDLING TOWING WINCH HANDLING TOWING WINCH This winch is for the D61EX-12. When installing it to the D61PX-12, change the track shoe to the 600 mm (23.6 in) narrow single shoe. If the winch is installed to machines with wider track shoes, the undercarriage may be damaged.
Page 231 ATTACHMENTS, OPTIONS HANDLING TOWING WINCH SAFETY LOCK (FOR WINCH) This lock (2) is used to lock the winch. When it is moved to the LOCK position, the winch control lever is locked. 6-10...
Page 232: Operation
ATTACHMENTS, OPTIONS HANDLING TOWING WINCH OPERATION WARNING Injury or death could result if the control lever is operated incorrectly during winch operations, so always do as fol- lows. Do not operate in a different way from the method given in this manual. Always wear leather gloves when handling wire rope.
Page 233: Inspection And Adjustment Before Starting Engine
ATTACHMENTS, OPTIONS HANDLING TOWING WINCH INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE WALK-AROUND CHECK Check wire rope If any abnormality is found, replace the wire rope. OPERATIONS AND CHECKS BEFORE STARTING ENGINE Before starting the engine, check the position of every lever. Check that winch lever (1) is at the N position.
Page 234 ATTACHMENTS, OPTIONS HANDLING TOWING WINCH WINDING IN When the winch control lever is moved from the N posi- tion to Normal rotation position (1), the brake is released and the wire rope is wound in. When stopping the winding-in operation, release the winch control lever.
Page 235 ATTACHMENTS, OPTIONS HANDLING TOWING WINCH SLOW WINDING OUT 1. When the winch control lever is moved from the N position to Slow reverse rotation position (3), the brake is released, the drum rotates slowly in reverse, and the wire rope is wound out. 2.
Page 236: Adjusting
ADJUSTING ADJUSTING CLUTCH If any abnormality is found, please contact your Komatsu distributor for inspection and repairs. ADJUSTING BRAKE If the wire rope can be wound out from the drum when the winch control lever is at the N position, the brake is not working, so please contact your Komatsu distributor for inspection and repairs.
Page 237: Handling Wire Rope
ATTACHMENTS, OPTIONS HANDLING TOWING WINCH Loosen bolt (2). Watch the rotation of the drum and move adjustment plate (1) to the optimum position. After adjusting, tighten bolt (2) to hold the adjustment plate in position. HANDLING WIRE ROPE If the wire rope is repeatedly tensed and slackened, it will rapidly become damaged, so check it for damage before and after operations, and replace it if it is in the following condition.
Page 238: Service Procedure
ATTACHMENTS, OPTIONS HANDLING TOWING WINCH SERVICE PROCEDURE INITIAL 250 HOURS SERVICE Carry out the following maintenance after operating a new machine for the first 250 hours. Change gear case oil and clean strainer For details, see EVERY 1000 HOURS SERVICE. 6-17...
Page 239 ATTACHMENTS, OPTIONS HANDLING TOWING WINCH EVERY 1000 HOURS SERVICE CHANGE GEAR CASE OIL AND CLEAN STRAINER WARNING The oil is at high temperature after the machine has been operated. Always wait for the temperature to go down before starting this operation. Prepare the following.
Page 240: Specifications
If the oil level is low, add oil through oil filler (F). SPECIFICATIONS Power angle, power tilt dozer Item Unit D61EX-12 Operating weight 17,010 (not including operator) (lb) (37,507)
Page 241 ATTACHMENTS, OPTIONS HANDLING TOWING WINCH SUSPENSION SEAT (Deluxe seat) WARNING Adjust the seat position at the beginning of each shift or when opertors change. Adjust the seat so that the brake pedal can be depressed all the way with the operator's back against the backrest.
Page 242: Headrest
ATTACHMENTS, OPTIONS HEADREST HEADREST Removal of headrest Pull up the headrest. REMARK The headrest cannot be fixed to halfway. 6-21...
Page 243: Equipping The Fire Extinguisher And The 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 brackets, please contact your Komatsu distributor. 6-22...
Page 244: Index
INDEX INDEX ADJUSTING POSTURE OF GENERAL PRECAUTIONS ......2-8, 6-2 WORK EQUIPMENT ........3-79 GENERAL VIEW ..........3-2 AFTER COLD WEATHER ........3-99 GENERAL VIEW OF AFTER COMPLETION OF WORK ..... 3-99 CONTROLS AND GAUGES ......3-3 AFTER RUNNING OUT OF FUEL ....3-102 GENERAL VIEW OF MACHINE ......
Page 245 INDEX POSITION OF SERVICE METER ......1-9 WHEN REQUIRED ..........4-19 POSITIONS OF SAFETY PICTOGRAMS ....2-4 WORK POSSIBLE USING BULLDOZER ... 3-77 PRECAUTIONS FOR LOW TEMPERATURE ..3-97 PRECAUTIONS FOR MAINTENENCE ....2-27 PRECAUTIONS FOR OPERATION ..2-17, 3-75 PRECAUTIONS RELATED TO SAFETY ....6-2 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT ....3-88 PROPER SELECTION OF FUEL,...
Page 246 MEMO...

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