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Komatsu ecot3 D65EX-16 Operation & Maintenance Manual

Komatsu ecot3 D65EX-16 Operation & Maintenance Manual

Bulldozer

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BULLDOZER

Unsafe use of this machine may cause serious injury or

death. Operators and maintenance personnel must read

this manual before operating or maintaining this machine.

This manual should be kept near the machine for

reference and periodically reviewed by all personnel who

will come into contact with it.

Komatsu has Operation & Maintenance Manuals

written in some other languages. If a foreign language

manual is necessary, contact your local distributor for

availability.

D65EX

D65PX

D65WX

SERIAL NUMBERS

WARNING

NOTICE

TEN00488-03

-16

-16

-16

80159

and up

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Summary of Contents for Komatsu ecot3 D65EX-16

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 some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
Page 2 1 - 1...
Page 3 Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
Page 4 FOREWORD IMPORTANT SAFETY INFORMATION IMPORTANT SAFETY INFORMATION To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed.
Page 5 FOREWORD INTENDED USE INTENDED USE USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: Dozing Smoothing Cutting into hard or frozen ground or ditching Felling trees, removing stumps See the section "WORK POSSIBLE USING BULLDOZER (PAGE 3-136)" for further details.
Page 6 FOREWORD INTENDED USE VISIBILITY FROM OPERATOR'S SEAT The visibility standards (ISO 5006) for this machine require a view shown in the diagram below. PROXIMITY VISIBILITY The figure belows shows a front visibility from the machine at a spot 1.0 m away from the side and 1.5 m above the ground.
Page 7 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR When ordering replacement parts, please inform your Komatsu distributor of the following. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is at the bottom left at the front of the operator's seat.
Page 8 FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SERVICE METER POSITION The service meter is provided at the center of the machine monitor. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address Service Personnel...
Page 9 FOREWORD CONTENTS CONTENTS FOREWORD BEFORE READING THIS MANUAL IMPORTANT SAFETY INFORMATION INTENDED USE USE OF MACHINE GENERAL VIEW AND DIRECTIONS OF MACHINE VISIBILITY FROM OPERATOR'S SEAT LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE EPA REGULATION, ENGINE SERIAL NO.
Page 10 FOREWORD CONTENTS DOOR - OPEN LOCK 3- 69 SASH GLASS INTERMEDIATE LOCK 3- 69 DOOR POCKET 3- 70 ASHTRAY 3- 70 SHOVEL HOLDER 3- 70 CAR RADIO, HANDLING 3- 71 AIR CONDITIONER, HANDLING 3- 76 OPERATION 3- 90 CHECK BEFORE STARTING ENGINE, ADJUST 3- 90 STARTING ENGINE 3-111...
Page 11 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 12 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 13 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 14 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 15 TORQUE LIST...
Page 12 2 - 1...
Page 13 SAFETY SAFETY SAFETY SAFETY LABELS POSITIONS OF SAFETY PICTOGRAMS SAFETY LABELS GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 10 PRECAUTIONS BEFORE STARTING OPERATION 2- 10 ENSURING SAFE OPERATION 2- 10 UNDERSTANDING THE MACHINE 2- 10 PREPARATIONS FOR SAFE OPERATION 2- 10 PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 10...
Page 14 SAFETY SAFETY PRECAUTIONS FOR OPERATION 2- 18 PRECAUTIONS FOR JOBSITE 2- 18 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 18 WORKING ON LOOSE GROUND 2- 18 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 19 ENSURE GOOD VISIBILITY 2- 19 CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 19 BEWARE OF ASBESTOS DUST 2- 20...
Page 15 SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE 2- 29 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 29 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 29 KEEP WORKPLACE CLEAN AND TIDY 2- 29 SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 29 ONLY AUTHORIZED PERSONNEL 2- 29 APPOINT LEADER WHEN WORKING WITH OTHERS...
Page 16 When cleaning the labels, do not use organic solvents or gasoline. They may cause the labels to peel off. If the labels are damaged, lost, or cannot be read properly, contact your Komatsu distributor immediately regarding their replacement. For details concerning the part numbers for the labels, see this manual or the actual label.
Page 17 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) 2 - 6...
Page 18 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Caution for high-temperature coolant (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 back side of the cover of the track adjustment window.
Page 19 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (8) Caution for battery cable (09808-03000) (9) Caution for engine running (09667-03001) (10) Caution for approach when machine moving (09812-13000) (11) Jump start prohibited (09842-A0481) 2 - 8...
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (12) Caution when handling battery (09664-30011) (13) Caution for ROPS/FOPS (09620-A2000) (14) Caution for blast site (09845-00480) (only when equipped with KOMTRAX) 2 - 9...
Page 21 SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 22 SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE KEEP MACHINE CLEAN If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machine clean.
Page 23 SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE FIRE PREVENTION ACTION IF FIRE OCCURS Turn the start switch OFF to stop the engine. Use the handrails and steps to get off the machine. Do not jump off the machine. There is the danger of falling and suffering serious injury. PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, coolant or window washer fluid Do not bring any flame or fire close to flammable substances...
Page 24 SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Fire coming from piping Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire, serious personal injury or death.
Page 25 SAFETY SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Always face the machine and maintain at least 3 point contact (both feet and one hand, or both hands and one foot) with the handrail and steps to ensure that you support yourself.
Page 26 SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PRECAUTIONS WHEN LEAVING MACHINE If the proper procedures are not taken when parking the machine, the machine may suddenly move off by itself, and this may lead to serious personal injury or death. Always do the following. When leaving the machine, always lower the work equipment completely to the ground, set work equipment lock lever (1) and parking brake lever (2) to LOCK position (L), and stop the...
Page 27 If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always contact your Komatsu distributor for advice on the method of repair.
Page 28 SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING The engine exhaust gas contains substances that may damage your health or even cause death. Start or operate the engine in a place where there is good ventilation. If the engine or machine must be operated inside a building or under ground, where the ventilation is poor, take steps to ensure that the engine exhaust gas is removed and that ample fresh air is brought in.
Page 29 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting operations, always check the following to confirm that there is no danger on the jobsite. When carrying out operations near combustible materials such as attatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
Page 30 SAFETY PRECAUTIONS FOR OPERATION DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always do as follows.
Page 31 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 - 20...
Page 32 SAFETY PRECAUTIONS FOR OPERATION STARTING ENGINE USE WARNING TAGS If there is any "DANGER! Do NOT operate!" warning tag displayed, it means that someone is carrying out inspection and maintenance of the machine. If the warning sign is ignored and the machine is operated, there is danger that the person carrying out inspection or maintenance may be caught in the rotating parts or moving parts and suffer serious personal injury or death.
Page 33 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN STARTING Start and operate the machine only while seated. When starting the engine, sound the horn as a warning. Do not allow anyone apart from the operator to ride on the machine. Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious personal injury or death.
Page 34 SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION If the checks before starting are not carried out properly, the machine will be unable to display its full performance, and there is also danger that it may lead to serious personal injury or death. When carrying out the checks, move the machine to a wide area where there are no obstructions, and pay careful attention to the surrounding area.
Page 35 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING Never turn the starting switch key to OFF position when the machine is traveling. If the engine stops when the machine is traveling, it may become impossible to operate the steering, and this may cause serious personal injury or death.
Page 36 SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. Keep the work equipment approximately 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, lower the work equipment to the ground immediately to help stop the machine.
Page 37 SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SNOW-COVERED OR FROZEN SURFACES 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 38 The machine can be divided into parts for transportation, so when transporting the machine, 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 39 SAFETY PRECAUTIONS FOR OPERATION TOWING PRECAUTIONS WHEN TOWING Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or towing bar or in the method of towing a disabled machine may lead to serious personal injury or death. For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-167)"...
Page 40 SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE Always display the "DANGER! Do NOT operate" warning tag during the inspection and maintenance. If there is any "DANGER! Do NOT operate!" warning tag displayed, it means that someone is carrying out inspection and maintenance of the machine.
Page 41 SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Lower the work equipment completely to the ground and stop the engine before performing any inspection and maintenance. Turn the starting switch to ON position, operate the work equipment control lever to RAISE and LOWER position 2 or 3 times repeatedly to release the remaining pressure in the hydraulic circuit, then set parking brake lever (1) and work...
Page 42 SAFETY PRECAUTIONS FOR MAINTENANCE 2 WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal 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 2 workers and do as follows. 1 worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 43 SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT Make sure the hoists or jacks you use are in good repair and strong enough to handle the weight of the component. Never use jacks at places where the machine is damaged, bent, or twisted.
Page 44 SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE PRECAUTIONS WHEN WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.
Page 45 SAFETY PRECAUTIONS FOR MAINTENANCE Danger of sparks There is hazard that sparks will be generated, so always observe the following. Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools lying around near the battery.
Page 46 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 47 If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. It is necessary to disassemble the recoil spring assembly, always ask your Komatsu distributor to carry out the operation.
Page 48 Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Contact your Komatsu distributor to have this work performed. PRECAUTIONS WITH COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious personal injury caused by flying dust or particles.
Page 49 SAFETY PRECAUTIONS FOR MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To enable this machine to be used safely for a long period, always carry out periodic replacement of safety critical parts that have a particularly close relation to safety, such as hoses and the seat belt. For details of the replacement of safety critical parts, see "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 4-16)".
Page 50 3 - 1...
Page 51 OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Sigma dozer Power angle power tilt dozer Blade Track shoe Blade tilt cylinder Sprocket Blade lift cylinder Track frame Blade angle cylinder Frame ROPS cab (10) Idler 3 - 2...
Page 52 OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Parking brake lever Rear lamp switch Work equipment lock lever Starting switch Cigarette lighter (10) Brake pedal Fuel control dial (11) Deceleration pedal Steering, forward-reverse, gear shift lever (12) Blade control lever Machine monitor (13) Horn switch...
Page 53 OPERATION GENERAL VIEW DD: Check before starting screen BB: Screen with all lamps lighted up CC: Maintenance time warning screen Air conditioner switch (15) Reverse slow mode monitor Buzzer cancel switch (16) ECO indicator Operating mode selector switch (17) Fuel gauge Function switch (18) Power train oil temperature monitor,...
Page 54 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. MACHINE MONITOR DD: Check before starting screen BB: Screen with all lamps lighted up...
Page 55 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR STARTING ENGINE WHEN SITUATION IS NORMAL When the starting switch is turned to ON position, the opening screen GG is displayed. After the opening screen GG is displayed for 2 seconds, the screen switches to the check before starting screen After the check before starting screen DD is displayed for 2 seconds, the screen switches to the mode display screen HH.
Page 56 OPERATION EXPLANATION OF COMPONENTS STOPPING ENGINE WHEN SITUATION IS NORMAL When the starting switch is turned to OFF position, ending screen JJ is displayed for 5 seconds, then the display goes out. 3 - 7...
Page 57 OPERATION EXPLANATION OF COMPONENTS IF THERE IS ABNORMALITY WHEN STARTING SWITCH IS TURNED ON If there is any abnormality when the starting switch is turned ON, the check before starting screen DD changes to the maintenance time warning screen CC, warning screen FF, or error screen EE. After displaying the check before starting screen DD for 2 seconds, the screen changes to the maintenance time warning screen CC.
Page 58 OPERATION EXPLANATION OF COMPONENTS IF ANY ABNORMALITY OCCURS DURING OPERATION If any abnormality occurs during operation, the standard screen AA changes to warning screen FF-(1) or the error screen EE. After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen FF-(2). 3 - 9...
Page 59 OPERATION EXPLANATION OF COMPONENTS EMERGENCY MONITORS CAUTION If the monitor lights up in red, stop the engine immediately or run at low idle, check applicable location, then perform necessary actions. These items should be observed while the engine is running. If there is a problem, the monitor for the abnormal location lights up in red and buzzer sounds, perform action immediately.
Page 60 OPERATION EXPLANATION OF COMPONENTS POWER TRAIN OIL TEMPERATURE MONITOR, HYDRAULIC OIL TEMPERATUREMONITOR This monitor (2) warns of an abnormal rise of power train oil temperature (A) and hydraulic oil temperature (B). When the temperature becomes abnormally high, an abnormality symbol is displayed, the overheat prevention system operates, and the engine output lowers.
Page 61 OPERATION EXPLANATION OF COMPONENTS CAUTION MONITORS CAUTION If the warning monitor lights up in red, stop operations as soon as possible and perform inspection and maintenance of the applicable location. If the warning is ignored, it may lead to failure. NOTICE Stop the machine on level ground and check the monitor.
Page 62 OPERATION EXPLANATION OF COMPONENTS WATER SEPARATOR MONITOR This monitor (2) warns the operator when water has accumulated inside the water separator. If the red lamp lights up, stop the engine, then drain the water separator. For details of the method of draining the water from the water separator, see "CHECK, DRAIN WATER SEPARATOR (PAGE 3-94)".
Page 63 For details of the method of checking the maintenance interval, see "MAINTENANCE MODE SELECTOR SWITCH (PAGE 3-29)". If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings. 3 - 14...
Page 64 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY PORTION Air conditioner monitor Engine pre-heating monitor Message monitor (only machines equipped Operation mode monitor with KOMTRAX) Reverse slow mode monitor (10) ECO indicator Engine coolant temperature gauge (11) Fan reverse monitor Fuel gauge (12) Parking brake monitor Multi-gauge...
Page 65 OPERATION EXPLANATION OF COMPONENTS PILOT DISPLAY The pilot display at the top of the screen consists of the pilot lamps to confirm the actuation of each function. When the starting switch is turned ON, the pilot lamp lights up when the display items are functioning. ENGINE PRE-HEATING MONITOR This monitor (1) displays the preheating time needed when starting the engine in temperatures below -3°C (26.6°F).
Page 66 OPERATION EXPLANATION OF COMPONENTS GAUGES AND METER ENGINE COOLANT TEMPERATURE GAUGE This meter (4) shows the engine coolant temperature. During normal operations, the indicator should be in the green range. If the indicator enters the red range during operations, the overheat prevention system is actuated.
Page 67 OPERATION EXPLANATION OF COMPONENTS MULTI-GAUGE This gauge (6) displays a variety of items, but the following explanation describes the actuation for the power train oil temperature gauge and hydraulic oil temperature gauge. The indicator should be in the green range during operations. If the indicator enters the red range (A) during operation, it means that the oil temperature is too high.
Page 68 OPERATION EXPLANATION OF COMPONENTS SERVICE METER, CLOCK This meter (7) shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even if the machine is not moving. The service meter advances 1 for every hour that the machine is working, regardless of the engine speed.
Page 69 Monitor off: Air conditioner OFF MESSAGE MONITOR (ONLY MACHINES EQUIPPED WITH KOMTRAX) This monitor (9) lights up when there is a message from Komatsu. Press function switch F6 on the user menu to display the message. Lighted up in green: There is unread message...
Page 70 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE MONITOR This monitor (12) lights up when the parking brake lever is in the LOCK position. It goes OFF when the parking brake lever is set in the FREE position. WORK EQUIPMENT LOCK MONITOR This monitor (13) lights up when the work equipment lock lever is in the LOCK position.
Page 71 OPERATION EXPLANATION OF COMPONENTS MONITOR SWITCHES PORTION Operating mode selector switch Buzzer cancel switch Gear shift mode selector switch Function switches Customize switch Air conditioner switch Customize memory switch OPERATING MODE SELECTOR SWITCH This switch (1) is used to switch the operating mode of the engine. Normally, it is possible to carry out all operations in E mode, and this mode reduces fuel consumption.
Page 72 OPERATION EXPLANATION OF COMPONENTS GEAR SHIFT MODE SELECTOR SWITCH This switch (2) switches the gear shift mode to automatic shift mode and manual shift mode. In the automatic shift mode, the transmission shifts up automatically to the maximum set speed range, and shifts down according to the load.
Page 73 OPERATION EXPLANATION OF COMPONENTS CUSTOMIZE MEMORY SWITCH CAUTION To ensure safety, always stop the machine before changing the mode. With this switch (4) the items set for up to 5 people using the customize function can be saved, and it is possible to recall the settings the next time the machine is used.
Page 74 OPERATION EXPLANATION OF COMPONENTS BUZZER CANCEL SWITCH When this switch (5) is pressed, the warning buzzer for the abnormal warning item stops. FUNCTION SWITCHES Function switches (6) consist of 6 switches (F1 to F6). The function of each switch differs according to the content of each screen.
Page 75 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH The air conditioner switches (7) consist of 9 switches. For explanation of each switch, see "AIR CONDITIONER, HANDLING (PAGE 3-76)". 3 - 26...
Page 76 OPERATION EXPLANATION OF COMPONENTS HANDLING FUNCTION SWITCHES The function switches (A) at the bottom of the monitor display consist of 6 switches (F1 to F6). The function of each switch differs according to the content of each screen. The function of switches (A) on each screen can be confirmed by guidance icons (B) displayed on top of each switch.
Page 77 OPERATION EXPLANATION OF COMPONENTS SERVICE METER/CLOCK DISPLAY SELECTOR SWITCH On the standard screen, it is possible to press switch F4 to switch the service meter and clock display at the top of the monitor display. When the time is being displayed, press switch F4 to switch to the service meter display.
Page 78 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE MODE SELECTOR SWITCH When switch F5 is pressed on the standard screen, the monitor display screen switches to the maintenance mode screen. The items on the maintenance display are as follows. Change engine oil Replace engine oil filter Replace fuel main filter 1000 Replace fuel prefilter...
Page 79 If the time remaining until maintenance becomes 0 hours, the remaining time display is highlighted in red. If you want to change the setting for the maintenance due time, consult your Komatsu distributor. 3 - 30...
Page 80 OPERATION EXPLANATION OF COMPONENTS OPERATIONS ON MAINTENANCE TIME RESET SCREEN On the maintenance time reset screen, it is possible to carry out the following operations. F5: Cancels reset, returns to maintenance list screen F6: Resets remaining time, returns to standard screen If no switch is operated for 30 seconds on the maintenance time reset screen, the screen automatically returns to the standard screen.
Page 81 OPERATION EXPLANATION OF COMPONENTS USER MODE SELECTOR SWITCH When the switch F6 is pressed, the monitor display screen switches to the setting mode screen for the machine. On the User Menu screen, it is possible to carry out the following operations with switches F3 to F6.
Page 82 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following items can be set. a: Utility Screen b: Multi-gauge c: Screen Adjustment d: Time Adjustment e: Language Setting f: Message display g: Fan Reverse 3 - 33...
Page 83 OPERATION EXPLANATION OF COMPONENTS The operation to set from "a" through "g" is as follows. UTILITY SCREEN When the utility graph is selected with switch F6, it becomes possible to select the Standard Display, Load Display, or Body Pitch Display. Use switches F3 or F4 to select the item, then press switch F6 to confirm.
Page 84 OPERATION EXPLANATION OF COMPONENTS MULTI-GAUGE With this monitor, it is possible to select the gauge that is displayed in the center. Use switches F3 or F4 to select the item, then press switch F6 to confirm. NO. Multi-gauge selection item Remarks P/L oil Temperature There is a caution lamp...
Page 85 OPERATION EXPLANATION OF COMPONENTS An approximate value indicated by the gauge is as follows. Engine speed (1) 500 rpm (2) 1,000 rpm (3) 1,500 rpm (4) 2,000 rpm (5) 2,500 rpm (6) 3,000 rpm Battery voltage (1) 0 V (2) 17 V (3) 20 V (4) 25 V (5) 30 V...
Page 86 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Hydraulic pressure (1) 0 MPa (2) 10 MPa (3) 20 MPa (4) 30 MPa (5) 40 MPa (6) 50 MPa ADJUSTING SCREEN Use this screen adjustment menu to adjust the brightness, contrast, and back light of the screen. 1.
Page 87 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Select item to be adjusted (a) or (b) from the selection menu screen for screen adjustment, then press switch F6. The screen switches to the setting screen for the selected item. (a): Standard screen adjustment (b): Camera screen adjustment (only machines equipped with camera)
Page 88 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS On the screen for Items 1) and 2), it is possible to carry out the following operations with switches F2 to F6. F2: Resets all adjusted values to default value F3: Indicator of selected item moves 1 segment to left. F4: Indicator of selected item moves 1 segment to right.
Page 89 OPERATION EXPLANATION OF COMPONENTS CLOCK ADJUSTMENT On this clock adjustment menu, it is possible to change the setting of the clock displayed on the pilot monitor of the standard display. 1. On the standard screen, press switch F6. 3 - 40...
Page 90 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 2. Select "Clock Adjustment" on the user menu, then press switch F6. The screen switches to the time adjustment selection menu screen. The following 3 items can be changed. (a) Clock setting (b) 12/24 hour display mode (c) Daylight saving time 3 - 41...
Page 91 OPERATION EXPLANATION OF COMPONENTS 3. On the clock adjustment selection screen, it is possible to carry out the following operations with switches F3 to F6. Time Adjust the hour setting. 1) If "Time" (a) is not highlighted in yellow, press switch F6 to highlight "Time"...
Page 92 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 2) When minute display (c) is highlighted in orange, operate the switches as follows to adjust minute display (c). If it is not necessary to change the minute setting, press switch F6. If the time has been changed, always press switch F6.
Page 93 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Daylight Saving Time (Summer time) 1) If daylight saving time is turned ON (a), the clock display becomes 1 hour earlier. If daylight saving time is turned OFF (b), the clock display returns to the set time. The selected display mode is highlighted in green.
Page 94 OPERATION EXPLANATION OF COMPONENTS LANGUAGE SELECTION On this language selection menu, it is possible to select the language used on the monitor display. The languages that can be selected are as follows. Japanese, English, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish 1.
Page 95 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Select the language to use for the display, then press switch F6. The screen display changes to the selected language. On the language selection screen, it is possible to carry out the following operations with switches F3 to F6.
Page 96 EXPLANATION OF COMPONENTS MESSAGE DISPLAY (Machines equipped with KOMTRAX) On machines equipped with KOMTRAX, it is possible to see the messages from your Komatsu distributor on this message display menu. REMARK At present, there is no territory where it is possible to the use the message service.
Page 97 OPERATION EXPLANATION OF COMPONENTS HYDRAULIC DRIVE FAN REVERSE MODE CAUTION In this mode, the fan cannot be rotated in reverse with the engine running. Keep parking brake lever and work equipment lock lever in LOCK position. The machine cannot be driven while the fan is rotating in reverse. To release the cooling fan from a reverse rotation, turn the fuel control dial to MIN position, then turn the starting switch to OFF position and stop the engine.
Page 98 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS When this mode is selected, the screen in the diagram on the right appears. When screen (A) is being shown, press switch F6 to complete the preparations for rotating the fan in reverse. When screen (B) is being shown, the engine can be started.
Page 99 OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting switch Cigarette lighter (24V) Horn switch Accessory socket (12V) Room lamp switch Front lamp switch Wiper switch Rear lamp switch STARTING SWITCH This switch (1) is used to start or stop the engine. (A): OFF position Electric system loses the current and engine stops.
Page 100 OPERATION EXPLANATION OF COMPONENTS 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. ROOM LAMP SWITCH This (3) illuminates the room lamp. OFF position: Lamp is out ON position: Lamp lights up WIPER SWITCH...
Page 101 When installing the cab, check the colors and install the washer tank and each window washer hose correctly. When installing the cab, carry out the operation in accordance with the cab installation procedure manual held by your Komatsu distributor. 3 - 52...
Page 102 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS For left (blue) For right (red) For rear (black) For front (colorless) Washer tube (tank side) Washer tube (cab side) Left door (blue) Right door (red) Rear window (black) Front window (colorless) CIGARETTE LIGHTER This lighter (5) is used to light cigarettes.
Page 103 OPERATION EXPLANATION OF COMPONENTS HEAD LAMP SWITCH Use this switch (7) to light up the front lamps. Positions (a) and (b): Lighted up REMARK If the switch is pressed at the moon mark end (a), the monitor panel lighting becomes dimmer. (Nighttime mode) If the switch is pressed at the sun mark end (b), the monitor panel lighting does not become dimmer.
Page 104 OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Fuel control dial Parking brake lever Steering, forward-reverse, gear shift lever Work equipment lock lever Brake pedal Blade control lever Deceleration pedal Ripper control lever (if equipped) FUEL CONTROL DIAL Dial (1) is used to control the engine speed and output. (a) Low idle (MIN) position: Turn fully to the left (b) High idle (MAX) position: Turn fully to the right REMARK...
Page 105 OPERATION EXPLANATION OF COMPONENTS STEERING, FORWARD-REVERSE, GEAR SHIFT LEVER (PCCS lever) This lever (2) is used to switch between forward and reverse, to steer the machine, or carry out counterrotation turns. REMARK PCCS: Palm command control system Your machine may not be equipped with this adjustment machinery, depending on your machine's specifications.
Page 106 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Operating counter-rotation turn WARNING When operating the counter-rotation turn, if the load on the left and right is not balanced, the machine may make a pivot turn, so check the ground conditions and be careful not to hit any obstacles when carrying out the operation.
Page 107 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE LEVER WARNING When parking the machine, always set the parking brake lever to LOCK position. This lever (5) is used to apply the parking brake. REMARK Before moving the parking brake lever to LOCK position, return the joystick (steering, directional, and gear shift lever) to N position.
Page 108 OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER SIGMA DOZER Lever (7) is used to operate 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. Tilting control (A) RIGHT TILT (B) LEFT TILT...
Page 109 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS (D) REAR PITCH: Cutting angle is decreased. (E) FORWARD PITCH: Cutting angle is increased. REMARK The blade can be pitched when lever (7) is in the raise, hold or lower position. To pitch the blade, operate lever (7) to the left (D) or right (E) while depressing pitch button (C). When the blade is about the neutral cutting angle (pitch angle), the cylinder rod starts appearing from the right cylinder cover bottom (F position).
Page 110 OPERATION EXPLANATION OF COMPONENTS POWER ANGLE POWER TILT DOZER Lever (7) is used to operate 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. Tilting control (A) RIGHT TILT (B) LEFT TILT...
Page 111 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Angling control Turn the knob to the right or left to angle the blade. (C) LEFT ANGLE (D) HOLD: Blade is stopped and held in this position. (E) 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 112 OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR This is equipment to warn the operator that the air cleaner element has clogged up. For an element cleaning method, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-20)". FUSE NOTICE Before replacing a fuse, be sure to turn starting switch to OFF position. The fuses protect the electrical equipment and wiring from burning out.
Page 113 OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND CIRCUIT NAME Fuse box (1) Fuse Circuit capacity 20 A Starting switch 15 A Continuous power supply for controller 30 A Engine controller 15 A Continuous power supply for cab 15 A Power train controller ACC power source (engine) Horn Backup alarm...
Page 114 OPERATION EXPLANATION OF COMPONENTS FUSIBLE LINK NOTICE When replacing a fusible link, be sure to turn the power source (starting switch) OFF. If the starting switch does not work, any of the electrical equipment in the operator's cab does not work, or the pre-heater does not work, a fusible link built in the wiring harness is suspected to be disconnected.
Page 115 OPERATION EXPLANATION OF COMPONENTS ELECTRIC POWER TAKE-OUT ADAPTER In-cab electric power take-out adapter 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 24 V equipment and the accessory socket (2) can be used for 12 V equipment.
Page 116 OPERATION EXPLANATION OF COMPONENTS OIL FILLER CAP METHOD OF OPENING AND CLOSING HYDRAULIC TANK FILLER CAP The method of opening or closing the hydraulic tank filler cap is as follows. Use the starting switch key to open and close the cap. OPENING THE CAP 1.
Page 117 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPENING AND CLOSING FUEL TANK CAP The method of opening or closing the fuel tank cap is as follows. OPENING THE CAP 1. Raise lever (1) in the (a) direction. 2. When lever (1) is turned in the (c) direction (counterclockwise) by approximately 35 deg., it stops at the stopper, and the cap can be opened.
Page 118 OPERATION EXPLANATION OF COMPONENTS DOOR - OPEN LOCK (Machine 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 119 OPERATION EXPLANATION OF COMPONENTS DOOR POCKET (Machine equipped with cab) These are inside the left and right doors and can be used for keeping small objects. Do not put heavy objects such as tools in the pockets. If the pocket is dirty, turn 3 bolts (1), remove the pocket, and wash it in water.
Page 120 OPERATION EXPLANATION OF COMPONENTS CAR RADIO, HANDLING (Machine equipped with cab) EXPLANATION OF COMPONENTS Power switch, volume knob Seek button (SEEK) Tone control knob Tuning button Display Preset station buttons Display selector button (CLOCK) FM/AM selector button (BAND) Station selector button (AST) POWER SWITCH, VOLUME KNOB When this knob (1) is turned clockwise from OFF position, a click is heard and the power is turned on.
Page 121 OPERATION EXPLANATION OF COMPONENTS STATION SELECTOR BUTTON (AST) When this button (5) is pressed, the preset stations are called up in turn. When the desired broadcasting station is reached, press the button again to stop it. If this button is kept pressed for 2 seconds, it switches to auto memory. SEEK BUTTON (SEEK) When this button (6) is pressed, it automatically searches for stations that can be received.
Page 122 OPERATION EXPLANATION OF COMPONENTS METHOD OF AUTOMATIC TUNING When SEEK button (6) is pressed, the frequency will move up to a channel that can be received, and then will stop automatically. METHOD OF MANUAL TUNING ∨ If the part of TUNE button (7) is pressed, the frequency will go ∧...
Page 123 OPERATION EXPLANATION OF COMPONENTS METHOD OF USING AUTO MEMORY If AST button (5) is kept pressed for 2 seconds, the broadcasting stations that can be received in the area are called up in turn, and the broadcasting stations are automatically saved in the preset memory.
Page 124 OPERATION EXPLANATION OF COMPONENTS ANTENNA NOTICE When transporting the machine or when parking it in a garage, lower the antenna and make sure that it does not contact anything. PRECAUTIONS WHEN USING To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during operation. If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water on the equipment.
Page 125 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER, HANDLING GENERAL LOCATIONS OF CONTROL PANEL OFF switch FRESH/RECIRC selector switch Fan switch Display monitor Temperature control switch Air conditioner switch Vent selector switch Sunlight sensor Auto switch OFF SWITCH Switch (1) is used to stop the fan and air conditioner. REMARK Even if this switch (1) is pressed, the monitor screen does not switch to the air conditioner adjustment screen.
Page 126 OPERATION EXPLANATION OF COMPONENTS FAN SWITCH Switch (2) is used to adjust the air flow. The air flow can be adjusted to 6 levels. Press the E switch to increase the air flow; press the R switc h to decrease the air flow. During auto operation, the air flow is automatically adjusted.
Page 127 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH Switch (3) is used to control temperature inside the cab. The temperature can be set between 18°C (64.4°F) and 32°C (89.6° Press the E switch to raise the set temperature; press the R switch to lower the set temperature.
Page 128 OPERATION EXPLANATION OF COMPONENTS (A1): Face vent (right and left 1 place) (A2): Rear vent (2 places) (A3): Front vent (2 place) (B): Foot vent (2 place) (C1): Door glass vent (right and left 1 places) (C2): Front window glass vent (1 place) 3 - 79...
Page 129 OPERATION EXPLANATION OF COMPONENTS AUTO SWITCH With switch (5), the air flow, vents, and air source (RECIRC/FRESH) are automatically selected according to the set temperature. Press switch (5), then use temperature control switch (3) to set the temperature, and run the air conditioner under automatic control.
Page 130 OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER SWITCH Switch (8) is used to turn the air conditioner (cooling, dehumidifying, heating) ON or OFF. Press air conditioner switch (8) when the fan is operating (when display (b) is shown on the display monitor). The air conditioner is switched ON and starts to work.
Page 131 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION The air conditioner can be operated automatically or manually. Select the method of operation as desired. AUTOMATIC OPERATION 1. Turn auto switch (5) ON. The monitors for the set temperature (a) and air flow (b) are also displayed.
Page 132 OPERATION EXPLANATION OF COMPONENTS STOPPING AUTOMATIC OPERATION Press OFF switch (1). Operation stops. MANUAL OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the monitor. 2.
Page 133 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Press temperature setting switch (3) and adjust temperature inside the cab. 4. Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the display monitor changes according to the selection.
Page 134 OPERATION EXPLANATION OF COMPONENTS STOPPING MANUAL OPERATION Press OFF switch (1). Operation stops. OPERATION WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blowing to the feet, set as follows. 1.
Page 135 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Turn air conditioner switch (8) ON. 4. Adjust fan switch (2), temperature setting switch (3) and RECIRC/FRESH selector switch (6) to the desired positions. 3 - 86...
Page 136 OPERATION EXPLANATION OF COMPONENTS DEFROSTER OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the monitor. 2. Press vent selector switch (4) and set vent display on the display monitor to (f) or (g) as shown in figure on the right.
Page 137 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 3. Press RECIRC/FRESH selector switch (6) and set it to take in fresh air. 4. Press temperature setting switch (3) and set temperature on the display (7) monitor to maximum heating. When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, turn air conditioner switch (8) ON.
Page 138 If any abnormality is detected in any equipment or sensor used on the air conditioner, "A/C Controller Error" is displayed on the air conditioner monitor screen. If "A/C Controller Error" is displayed, ask your Komatsu distributor to carry out inspection and repair. 3 - 89...
Page 139 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 140 OPERATION OPERATION 7. Check for problems in handrails, steps, loose bolts. If any problem is found, repair it. Tighten any loose bolts. 8. 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 141 Always check the items in this section before starting the engine each day. CHECKING WITH MACHINE MONITOR 1. Turn starting switch (1) to ON position (B). 2. After the initial KOMATSU screen, check that the basic monitor screen is displayed and that the alarm buzzer sounds for approximately 2 seconds.
Page 142 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 143 OPERATION OPERATION REMARK When checking the oil level, if the machine is inclining, make it level before carrying out the check. When checking the oil level, check it before starting the engine, or at least 15 minutes after engine has been stopped.
Page 144 OPERATION OPERATION CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns.
Page 145 OPERATION OPERATION CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the operation. 1.
Page 146 Check the wiring of the "battery", "starting motor" and "alternator" carefully in particular. Always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Contact your Komatsu distributor for investigation and correction of the cause. CHECK BRAKE PEDAL TRAVEL WARNING If the brake pedal stroke is not 60 to 80 mm (2.4 to 3.1 in) (below 60 mm or over 80 mm), the brake and steering force is too strong...
Page 147 OPERATION OPERATION CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING When removing the oil filler cap, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap.
Page 148 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 149 Check that the horn sounds. If it does not sound at all or the sound is extremely feeble, a defect or broken wire is suspected, ask your Komatsu distributor for possible repairs. 1. Turn starting switch to ON position (B).
Page 150 3. Turn the rear lamp switch to position (a) to check that the rear lamps light up. If the lamps do not light, check for a broken bulb or disconnected wire, contact your Komatsu distributor for repairs. 3 - 101...
Page 151 OPERATION OPERATION CHECK OF OPERATION OF BACKUP ALARM 1. Turn starting switch to ON position (B). 2. Set the parking brake lever to the LOCK position. 3. Set the steering, forward-reverse, gear shift lever in the REVERSE position (R). The alarm must sound immediately at this time. The alarm keeps sounding until the steering, forward-reverse, gear shift lever is set to the NEUTRAL position (N) or FORWARD position (F).
Page 152 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 LOCK position to prevent any accidental contact with the control levers. WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. Adjust the seat position at the beginning of each shift or when operators change.
Page 153 OPERATION OPERATION (D) Seat angle adjustment 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). 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 154 OPERATION OPERATION AIR SUSPENSION SEAT (A) Fore-and-aft adjustment Pull lever (1), set the seat to a position where it is easy to operate, then release the lever. Fore-aft adjustment: 160 mm (6.3 in) (8 stages) (B) Weight and height adjustment of seat The seat height is adjusted pneumatically and in stepless by fully pressing down or pulling up lever (2).
Page 155 OPERATION OPERATION SEAT BELT WARNING Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions. Replace any worn or damaged seat belt or the securing brackets. Even if there are no signs of damage, replace belts in accordance with the following schedule: 5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes first.
Page 156 OPERATION OPERATION ADJUST MIRROR WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may injure someone seriously. Loosen nut (1) of the mirror and adjust the mirror to a position where it gives the best view from the operator's seat.
Page 157 OPERATION OPERATION ADJUST ARMREST The height of the armrests on the right and left sides of the operator's seat can be adjusted according to the following procedure. After adjusting the operator's seat, adjust the armrest height properly. ADJUST ARMREST (RIGHT) Arm rest (1) can be adjusted in four stages;...
Page 158 OPERATION OPERATION OPERATION AND CHECK BEFORE STARTING ENGINE WARNING When starting the engine, check and make sure the work equipment lock lever (4) and parking brake lever (1) are secured in LOCK position. If the control levers are not locked and they are touched by accident when starting the engine, the work equipment may move unexpectedly, and this may lead to a serious injury or death.
Page 159 OPERATION OPERATION OPERATION OPERATION REMARK The engine cannot be started if steering, forward-reverse, gear shift lever (2) is not in the N position. If steering, forward-reverse, gear shift lever (2) is in F or R, the letter P on display panel A will flash. 3.
Page 160 OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING Sit down in the operator's seat before starting the engine. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 161 OPERATION OPERATION OPERATION OPERATION 3. When the engine starts, release the key in starting switch (2). The key will return automatically to ON position (B). STARTING IN COLD WEATHER WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit.
Page 162 OPERATION OPERATION OPERATION OPERATION 2. Insert the key into starting switch (2) and turn the key to ON position (B). 3. Check that engine pre-heating monitor (3) on the monitor panel lights up. 4. Maintain the key in the ON position (B) until engine pre-heating monitor (3) goes off.
Page 163 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, engine pre heating monitor (3) will light up and preheating will start.
Page 164 In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 165 (2) enters green range (A) to (C). (A) to (B): Red range (A) to (C): Green range (C) to (D): White range 3. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 116...
Page 166 OPERATION OPERATION STARTING IN COLD WEATHER (AUTOMATIC WARMING-UP OPERATION) This machine is equipped with an automatic warming-up device. When the engine is started, if the engine coolant temperature is low (below 30 °C (86 °F)), the warming-up operation is carried out automatically.
Page 167 If the power train oil temperature is not raised sufficiently, it will take longer to accelerate to the maximum speed. 6. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 118...
Page 168 OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is stopped without allowing it to cool down, there is danger that the service life of various parts of the engine will be reduced. Except in emergencies, never stop the engine suddenly. If the engine overheats, do not stop it suddenly.
Page 169 OPERATION OPERATION MACHINE OPERATION MOVING MACHINE WARNING Before moving the machine, check that the area around the machine is safe, and always sound the horn before moving. Do not allow anyone to enter the area around the machine. The rear of the machine is a blind spot, so be extremely careful when traveling in reverse.
Page 170 OPERATION OPERATION OPERATION OPERATION 3. Operate blade control lever (3) and ripper control lever (4) to the RAISE position (a), raise the blade 40 to 50 cm (15.8 to 19.7 in) from the ground, and raise the ripper to the maximum height.
Page 171 OPERATION OPERATION STOPPING 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 brake lever (1) in LOCK position and insert blocks underneath the track shoes.
Page 172 OPERATION OPERATION SHIFTING GEARS Since gear can be shifted during machine travel, the machine need not to be stopped to shift gears. 1. Move joystick (steering, directional, and gear shift lever) (1) to the desired gear position to shift gears. GEARSHIFTING OPERATION The transmission speed will change when switch (a) or switch (b) is pushed.
Page 173 OPERATION OPERATION OUTLINE OF GEAR SHIFT MODES There are 2 gear shift modes: automatic shift mode and manual shift mode. Select the mode to match the use. Automatic shift mode This is the mode used for general dozing operations. If a load is applied, the transmission automatically shifts down, and when the load is removed, it automatically shifts up to the maximum set speed range.
Page 174 OPERATION OPERATION SETTING PRESET WITH SHIFT SWITCH OPERATION AT NEUTRAL Preset (speed range when moving machine off) and maximum speed range when traveling (automatic mode only) are set by operating the shift switch when the transmission is at neutral. Automatic mode Preset (speed range when moving machine off) and maximum speed range when traveling can be set.
Page 175 OPERATION OPERATION GEARSHIFTING OPERATION USING PRESET MODE FUNCTION Preset mode selection means the function that set the starting speed range beforehand. When the steering, forward-reverse, gear shift lever is in the N position, if UP switch (a) or DOWN switch (b) is pressed, the shift mode selection can be carried out.
Page 176 OPERATION OPERATION SHIFTING SPEED RANGE BY OPERATING SWIFT SWITCH WHEN TRAVELING It is possible to operate the shift switch when traveling to change the maximum set speed range when traveling (automatic shift mode) or speed range used when traveling (manual shift mode). Automatic shift mode Changing maximum set speed range when traveling When traveling forward: Possible to change maximum speed...
Page 177 OPERATION OPERATION OPERATION OPERATION Manual shift mode Changing maximum speed range used when traveling When traveling forward: Possible to change speed range used to F1 to F3 When traveling in reverse: Possible to change speed range used to R1 to R3 up switch (a): Each time it is pressed, speed range used goes up 1 range down switch (b): Each time it is pressed, speed range used goes...
Page 178 OPERATION OPERATION NOTICE Be careful not to come unnecessarily close to the edge of cliffs. When dropping soil at the edge of a cliff to build an embankment or landfill, always leave 1 load and use the next load to push the previous load over. When reaching the top of a hill, or at the instant when the load is dumped from a cliff, the load will suddenly drop and there is danger that the machine will suddenly increase speed, so depress the decelerator pedal to reduce the speed when dumping the load.
Page 179 OPERATION OPERATION SHIFTING BETWEEN FORWARD AND REVERSE WARNING When switching between FORWARD and REVERSE, first check that the direction of travel is safe. CAUTION There is no need to stop the machine even when switching between FORWARD and REVERSE. To increase safety, operator comfort, and the life of the transmission, leave the engine running at full speed, and always depress the decelerator pedal to lower the engine speed.
Page 180 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 soil. Never make a pivot turn at high speed. NORMAL TURNING To turn the machine while traveling, incline joystick (steering, directional, and gear shift lever) (1) in the direction of the turn.
Page 181 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 182 OPERATION OPERATION PRECAUTIONS FOR OPERATION PAY ATTENTION TO GAUGES If the red range of the power train oil temperature gauge lights up during operation, reduce the load and wait for the temperature to go down. PERMISSIBLE WATER DEPTH When operating in water, always keep the bottom of carrier rollers (1) above the surface of the water.
Page 183 OPERATION OPERATION PRECAUTIONS ON SLOPES BE CAREFUL OF FUEL LEVEL If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle of the machine or the swaying of the machine. This makes the engine stop, so be careful not to let the fuel level in the fuel tank become too low.
Page 184 OPERATION OPERATION PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY (Machine equipped with cab) WARNING The cab stays create blind spots. When operating, check carefully that there is no person or obstacle in the surrounding area. 3 - 135...
Page 185 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 186 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 187 OPERATION OPERATION RECOMMENDED MODE FOR EACH TYPE OF OPERATION ADVANTAGES OF EACH MODE When gear shift mode selector switch (1) is used, gear shift mode can be changed. Gear shift mode Advantages This mode is recommended for normal soil quality and operations, such as digging, hauling, grading, and leveling.
Page 188 OPERATION OPERATION AA: Screen for normal HH: Customize screen Gear shift mode selector switch Customize switch Operating mode selector switch For explanation of the method of setting the customize mode, see "CUSTOMIZE SWITCH (PAGE 3-23)". TABLE OF RECOMMENDED MODES Gear shift Operating Type of Reverse...
Page 189 OPERATION OPERATION ADJUSTING POSTURE OF WORK EQUIPMENT ADJUST ANGLE OF BLADE EDGE WARNING It is dangerous if the work equipment moves by mistake when adjusting angle of the blade edge. Set the work equipment in a stable condition, then stop the engine and lock the work equipment securely with the work equipment lock lever. Blade cutting edge angle (A) can be adjusted to meet soil conditions.
Page 190 OPERATION OPERATION SIGMA DOZER Turn the brace with bar handle (1) to extend a distance between the joints (B), and then blade cutting edge angle (A) increases. To decrease the angle, shorten the distance. Standard cutting angle (A) is 46 deg. Standard distance (B) between the joints is 1150 mm (45.31 in).
Page 191 OPERATION OPERATION Method of adjusting 1. Remove 2 bolts (2), then remove cover (3). 2. Insert a bar in hole (C) of rod (1) and turn rod (1). 3. When increasing distance (B) between the joints, set grease fitting (4) to cover hole (5). Be sure to set so since increasing distance (B) more can cause damage.
Page 192 OPERATION OPERATION ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT When assembling the work equipment, if the adjustment of the play is not carried out properly, excessive bending stress will be generated at all parts, and this will lead to cracks or breakage. Adjust the play of parts (1) to (4) to the correct value.
Page 193 OPERATION OPERATION ADJUSTING BRACE OF ANGLE BLADE WARNING It is dangerous if the work equipment moves by mistake when it is being adjusted. Move the machine to a horizontal place, stop the machine, and set the work equipment in a stable condition. Then stop the engine and set the work equipment lock lever securely to the LOCK position.
Page 194 OPERATION OPERATION OPERATION OPERATION 2. Loosen set bolt (1) of the brace. 3. Insert a suitable bar into hole (2) of the brace and turn it to adjust length (B) of the brace. Adjust respective lengths (B) of the right and left braces to the following length.
Page 195 OPERATION OPERATION ADJUST AMOUNT OF TILT ANGLE DOZER 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. NOTICE An amount of tilt (A) can be increased to a maximum of 400 mm (15.8 in).
Page 196 OPERATION OPERATION OPERATION OPERATION 2. Loosen the bolt (1) of the brace, insert a suitable bar into hole (2) of the brace, and turn it. CAUTION Do not adjust only either brace. If the length of only either brace is changed to adjust the tilt, an excessive bending stress may be applied to the center pin, which may be broken.
Page 197 OPERATION OPERATION METHOD OF ANGLING BLADE (Angle dozer) When dozing toward one side only, operate with angled blade. WARNING When adjusting the amount of angling, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the work equipment lock lever.
Page 198 OPERATION OPERATION ADJUSTING TILT FOR USING BLADE IN ANGLED POSTURE Angledozers only Perform the following adjustment to adjust the brace length properly. 1. Return the blade to the standard posture (non-angled posture). 2. Adjust the blade to the necessary tilt. 3.
Page 199 OPERATION OPERATION OPERATION OPERATION 3. Operate parking brake lever (4) to LOCK (L) position. 4. Operate blade control lever (5) and ripper control lever (6) to LOWER position (c) and lower the blade and ripper to the ground. 5. Place blade control lever (5) and ripper control lever (6) at HOLD position (b).
Page 200 OPERATION OPERATION CHECK AFTER FINISHING WORK BEFORE STOPPING ENGINE Check the engine coolant temperature, engine oil pressure, and fuel level on the machine monitor. AFTER STOPPING ENGINE 1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for any leakage of oil or coolant.
Page 201 OPERATION OPERATION LOCKING To prevent vandalism, there are locks in 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 covers (2) Battery inspection cover (3) Inspection cover for fuel tank drain valve(4) Cab door opener (5) (Machine equipped with cab) Hydraulic tank filler cap (6)
Page 202 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 on the blade until slipping stops.
Page 203 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. Perform periodical inspection and contact the Komatsu distributor in your area when machine has approached repairable limits and reversing limits.
Page 204 OPERATION OPERATION MEASURING HEIGHT OF GROUSER After taking up slack in track shoes, measure height at center of shoe as shown below. Standard dimension (h): 65 mm (2.6 in) Repair limits: 25 mm (1.0 in) MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 1.
Page 205 OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION MEANS When transporting the machine, choose the transportation method in reference to the weight and dimensions shown in "SPECIFICATIONS (PAGE 5-2)". Note that the machine specifications (weight and dimensions) vary depending on the kind of track shoes, blade, or other equipment.
Page 206 OPERATION TRANSPORTATION LOADING, UNLOADING WORK WARNING Since loading and unloading of the machine is dangerous, be extremely careful. When loading or unloading the machine, operate it slowly with the engine speed low and the transmission in the 1st gear. Use ramps having sufficient width, length, thickness, and strength. Install them securely and set their angle to 15 deg. or less. If the ramps are deflected appreciably, reinforce them with blocks.
Page 207 OPERATION TRANSPORTATION SECURING MACHINE NOTICE Be sure to lower the car radio antenna to the stow position (if the machine is equipped with a cab). Load the machine onto a trailer as follows: 1. Lower the work equipment slowly. (When transporting with work equipment installed) 2.
Page 208 OPERATION TRANSPORTATION UNLOADING WORK 1. 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 deg.
Page 209 This method of lifting applies to the standard specification machine. The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. For weight, see "SPECIFICATIONS (PAGE 5-2)".
Page 210 OPERATION TRANSPORTATION For machine equipped with ripper Fit the wire ropes at the center to both left and the right pivot shafts (2). Hang the rear wire rope to ripper beam (3). When lifting the machine, stop it on a level place, then observe the following procedure. 1.
Page 211 OPERATION TRANSPORTATION TRAVELING ON ROADS When traveling on paved roads, use flat shoes to protect their surface. Even when travelling a short distance, always place boards to protect the road surface. REMARK Note that the asphalt road becomes soft in summer. 3 - 162...
Page 212 NOTICE Use Komatsu genuine SUPERCOOLANT (AF-NAC) for the coolant. As a basic rule, we do not recommend the use of any coolant other than SUPERCOOLANT (AF-NAC). Coolant is already diluted with distilled water, so it is not flammable.
Page 213 OPERATION COLD WEATHER OPERATION REMARK Measure the specific gravity and calculate the charging rate from the following conversion table. Electrolyte 20 ° C 0 ° C -10 ° C -20 ° C Temperature (68 ° F) (32 ° F) (14 ° F) (-4 °...
Page 214 AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it.
Page 215 OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting the engine. PROCEDURE FOR BLEEDING AIR 1. Insert the key into the engine starting switch and turn the key to ON position (B).
Page 216 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. Moving a machine by towing is only used to move it to a place where it is possible to carry out inspection and maintenance.
Page 217 OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charging. When checking or handling the battery, stop the engine and turn the starting switch key to OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 218 OPERATION TROUBLESHOOTING PRECAUTIONS FOR BATTERY CHARGING If the battery is charged improperly, it may explode. Accordingly, charge it according to "IF BATTERY IS DISCHARGED (PAGE 3-168)" and the instruction manual attached to the charger, and observe the following items. Set the voltage of the charger to match the voltage of the battery to be charged.
Page 219 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 positive (+) and negative (-) terminals. When starting the engine with a booster cable, wear safety glasses and rubber gloves.
Page 220 OPERATION TROUBLESHOOTING STARTING ENGINE WARNING Always check that the work equipment lock lever is set to LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are in HOLD or NEUTRAL position. 1.
Page 221 TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Defective wiring...
Page 222 Automatic functions stop, some functions stop, but operation is possible Inspect after completing operations Ask your Komatsu distributor to carry out repairs After user action to stop engine, operations are possible without limit functions when engine is restarted.
Page 223 OPERATION TROUBLESHOOTING CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Machine does not stop even when...
Page 224 OPERATION TROUBLESHOOTING ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lack of oil in oil pan (air being Add oil to specified level.
Page 225 REMARK If no point of contact telephone number has been registered, no telephone number is displayed. It is necessary to register the telephone number, Ask your Komatsu distributor to carry out the registration. 3 - 176...
Page 226 4 - 1...
Page 227 Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE OILS: For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID: Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 228 MAINTENANCE GUIDE TO MAINTENANCE DUSTY WORKSITES: When working at dusty worksites, do as follows: Inspect the dust indicator frequently to see if the air cleaner is dirty or clogged. Clean the radiator core frequently to avoid clogging. Clean and replace the fuel filter frequently. Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Page 229 MAINTENANCE GUIDE TO MAINTENANCE CHECKS AFTER INSPECTION AND MAINTENANCE WORK: If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do the following: Checks after operation (with engine stopped) Have any inspection and maintenance points been forgotten? Have all inspection and maintenance items been performed correctly? Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped...
Page 230 When using H046-HM hydraulic oil, drain all the oil and fill with the specified amount of oil. Always use oil recommended by Komatsu. If any other oil is used, it will cause clogging of the filter. There is no problem if the new oil is mixed with the small amount of oil remaining in the piping and cylinders.
Page 231 COOLANT AND WATER FOR DILUTION Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Page 232 Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed.
Page 233 Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 234 MAINTENANCE OUTLINE OF SERVICE HANDLING HYDRAULIC SYSTEM During operations and after completion of operations, the hydraulic equipment is at a high temperature. During operations, it is also under high pressure, so when carrying out inspection and maintenance of hydraulic related equipment, be careful of the following points.
Page 235 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 236 MAINTENANCE WEAR PARTS LIST Weight Replacement Item Part No. Part Name Q'ty (kg(lb)) frequency 14X-72-51810 Cutting edge (center) 38.8 13G-72-61420 Cutting edge (side) 24.3 D65EX 14Y-71-11330 End bit (left) Power angle 14Y-71-11340 End bit (right) power tilt dozer (02090-11270) (Bolt) (32) (02290-11219) (Nut)
Page 237 RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 238 MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ASTM: American Society of Testing and Material 4 - 13...
Page 239 Note 1: HTHS ( High-Temperature High-Shear Viscosity 150°C (302°F)), specified by ASTM D4741 must be equal to or higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils. Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Page 240 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 241 These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance.
Page 242 MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q'ty Replacement interval Hose (main control valve - central drain block) Hose (main control valve - blade tilt relay block) Hose (blade tilt relay block - tilt cylinder) Hose (main control valve - blade lift relay tube) Hose (radiator guard upper part - lift cylinder) Hose (fan pump - fan motor)
Page 243 MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4- 20 CLEAN INSIDE OF COOLING SYSTEM 4- 24 CHECK TRACK TENSION, ADJUST 4- 27 CHECK AND TIGHTEN TRACK SHOE BOLTS 4- 29 REVERSE AND REPLACE END BITS AND CUTTING EDGES 4- 30...
Page 244 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 1000 HOURS SERVICE REPLACE FUEL MAIN FILTER CARTRIDGE 4- 71 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING PUMP STRAINER) 4- 74 REPLACE HYDRAULIC TANK BREATHER ELEMENT 4- 76 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 4- 77 CHANGE OIL IN FINAL DRIVE CASE 4- 78...
Page 245 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 damage it. Be sure to stop the engine before carrying out these operations. If compressed air is used, there is danger that dirt may be blown around and cause serious injury.
Page 246 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE NOTICE Do not leave or keep the filter element in a place where it will be exposed to the direct sunlight before and after cleaning it. Never remove inner element (5). If it is removed, dirt will enter and can cause an engine trouble.
Page 247 MAINTENANCE MAINTENANCE SERVICE PROCEDURE 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. 13. If the yellow piston in dust indicator (1) overlaps the red zone on the outer diameter immediately after the outer element is cleaned, replace both the inner and outer elements.
Page 248 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. Replace O-ring (7) for cover (3) with new one. 8. Set the arrow mark on cover (3) at the top, install to the air cleaner body, then secure with clip (2). 9. Push the button of dust indicator (1) and return the yellow piston to its original position.
Page 249 (AF-NAC) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with SUPERCOOLANT (AF-NAC).
Page 250 When changing the coolant or when handling the cooling water containing coolant that has been drained during repair of radiator, contact your Komatsu distributor or request a specialist company to carry out the operation. Coolant is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 251 MAINTENANCE SERVICE PROCEDURE 10. To remove air in the cooling system, run the engine for 5 minutes at low idle, then for 5 minutes at high idle. (While doing this, leave the radiator cap removed.) 11. Drain the coolant from sub-tank (4), clean the inside of the sub-tank, then add coolant until the coolant level is between the FULL and LOW marks.
Page 252 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, contact your Komatsu distributor. WHEN INCREASING TENSION Prepare a grease pump.
Page 253 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, contact your Komatsu distributor. 1. Loosen plug (1) gradually to release the grease.
Page 254 MAINTENANCE SERVICE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS Track shoes may be broken, if they are used with loosened shoe bolts (1). Hence whenever a loosened bolt is found, be sure to retighten it. METHOD OF TIGHTENING (TRACK SHOE BOLTS) 1.
Page 255 MAINTENANCE SERVICE PROCEDURE REVERSE AND REPLACE END BITS AND CUTTING EDGES WARNING It is dangerous if the work equipment moves during the turning or replacement operation. Set the work equipment in a stable condition, set the work equipment lock lever to the LOCK position, then stop the engine. Reverse or replace the end bits and cutting edges before it is worn out to the blade end.
Page 256 MAINTENANCE SERVICE PROCEDURE 4. Remove the cutting edge and the end bit and clean the mounting surface. 5. Reverse or replace the cutting edge and the end bit when worn out. 1) Remove nut (1) and bolt (2), then replace or reverse the cutting edge and the end bit.
Page 257 MAINTENANCE SERVICE PROCEDURE CLEAN AND CHECK RADIATOR FINS AND OIL COOLER FINS Carry out this procedure if there is any mud or dirt stuck to the radiator or oil cooler. REMARK Check the hydraulic cooler hoses. If any hose is cracked or hardened by age, replace with a new hose. Also check and tighten all loose hose clamps.
Page 258 MAINTENANCE SERVICE PROCEDURE 5. Turn starting switch (1) to START position and start the engine. The cooling fan will rotate in the reverse direction. 6. Run the engine at high idle. Select the time for running the engine at high idle as follows according to the condition of clogging. Normal clogging: 1 to 2 minutes Excessive clogging: 2 to 3 minutes 7.
Page 259 MAINTENANCE SERVICE PROCEDURE CLEANING OF OIL COOLER FINS AND CONDENSER FINS 1. Open the right and left engine side covers. 2. Use compressed air to remove the mud, dirt, and leaves clogging hydraulic oil cooler fins (1) and condenser fins (2). Steam or water may be used instead of compressed air.
Page 260 MAINTENANCE SERVICE PROCEDURE CLEAN HYDRAULIC TANK BREATHER 1. Remove nut (2) of breather assembly (1) at the top of the hydraulic tank, then remove cover (3). 2. Remove dirt stuck to breather element (4) and wash it with clean light oil or detergent oil. 3.
Page 261 MAINTENANCE SERVICE PROCEDURE REPLACE FUEL TANK BREATHER ELEMENT NOTICE Note that the fuel tank breather and hydraulic tank breather have different part numbers. (The element is common to both. For details, see "WEAR PARTS LIST (PAGE 4-10)".) Fuel tank breather part No.: 22U-60-21520 1.
Page 262 MAINTENANCE SERVICE PROCEDURE CHECK, ADJUST AIR CONDITIONER (Machine equipped with cab) CHECKING TENSION OF COMPRESSOR BELT If the driving belt slackens, it is likely to slip, lowering the cooling efficiency. Depress the mid point between drive pulley (1) and compressor pulley (2) with a thumb (approximately 98 N (10 kg)) every now and then to make sure that deflection amount (A) is approximately 15 mm to 18 mm (0.59 to 0.71 in).
Page 263 MAINTENANCE SERVICE PROCEDURE REPLACE AIR CONDITIONER BELT 1. Loosen 2 bolts (1) and jack bolt (2), then move compressor (3) to the side. 2. Replace the V-belt. When adjusting the V-belt, do not push the compressor directly with the bar. Use jack bolt (2). 3.
Page 264 MAINTENANCE SERVICE PROCEDURE REPLACE DOOR DAMPER (Machine equipped with cab) If depth (A) of the groove of door damper rubber (1) is less than 2 mm (0.08 in), replace the damper. There are 4 dampers: 1 each at the top and bottom on the left and right doors.
Page 265 MAINTENANCE SERVICE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (Machine equipped with cab) Perform this check when the window washer fluid does not come out. Open the battery cover at the rear of the machine and check the level of the fluid in window washer tank (1). If it is low, add automobile window washer fluid.
Page 266 MAINTENANCE SERVICE PROCEDURE REPLACE WIPER BLADE (Machine equipped with cab) If the blade is damaged, it will not wipe the window clean, so replace the blade. REPLACEMENT FRONT, DOOR WIPER 1. It is hooked at portion (A), so move the blade in the direction of the arrow to remove it.
Page 267 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 repair. 4. Install guide plate (2) and shim (3) with bolt (1).
Page 268 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 269 MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM See "STARTING ENGINE (PAGE 3-111)". 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 270 MAINTENANCE SERVICE PROCEDURE ADJUSTING SHIMS, ADJUSTING TENSION AT WORK EQUIPMENT LINKS When assembling the work equipment, carry out adjustment as follows. Check the play of the links periodically and carry out adjustment. When disassembling the machine for transportation, be careful not to lose the shims. NEED FOR ADJUSTING WORK EQUIPMENT LINKS CAUTION If the clearances at each ball joint of the work equipment and the tension of the center brace are not adjusted properly, it will lead...
Page 271 MAINTENANCE SERVICE PROCEDURE LOCATIONS FOR ADJUSTMENT AND NEED FOR ADJUSTMENT WARNING It is dangerous if the work equipment moves by mistake when it is being adjusted. Move the machine to a horizontal place, stop the machine, and set the work equipment in a stable condition. Then stop the engine and set the work equipment lock lever securely to the LOCK position.
Page 272 MAINTENANCE SERVICE PROCEDURE METHOD OF ADJUSTING EACH LOCATION ADJUSTING SHIMS AT TILT BRACE, TILT CYLINDER HEAD, PITCH CYLINDER HEAD Correct value for play at ball joint: 0.2 to 0.7 mm Standard shim thickness: 5 mm Use the following procedure to adjust the play at the ball joint to the correct value. 1.
Page 273 MAINTENANCE SERVICE PROCEDURE ADJUSTING SHIMS AT LIFT CYLINDER HEAD Correct value for play at ball joint: 0.2 to 0.7 mm Standard shim thickness: 4 mm Use the following procedure to adjust the play at the ball joint to the correct value. 1.
Page 274 MAINTENANCE SERVICE PROCEDURE ADJUSTING SHIMS AT CENTER BRACE Correct value for play at ball joint: 0.2 to 0.7 mm Standard shim thickness: 5 mm Use the following procedure to adjust the play at the ball joint to the correct value. 1.
Page 275 MAINTENANCE SERVICE PROCEDURE ADJUSTING SHIMS AT TRUNNION Correct value for play at ball joint: 0.2 to 1.2 mm Standard shim thickness: 10 mm Use the following procedure to adjust the play at the ball joint to the correct value. 1. Remove bolts (1), then remove cap (2). 2.
Page 276 MAINTENANCE SERVICE PROCEDURE ADJUSTING TENSION OF CENTER BRACE (Straight tilt dozer) (Straight tilt power pitch dozer) (Sigma dozer) (Sigma power pitch dozer) In case the work equipment assembly is disassembled for transportation and reassembled at a worksite, tension of the center brace has to be adjusted anew. Otherwise the bushing at the connecting part of blade and straight frame will likely slip off, allowing sand and dirt to enter the bushing, which eventually leads to premature wear or damage of the bushing.
Page 277 MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-92)" in the OPERATION section. Checking with machine monitor Check oil level in engine oil pan, add oil Check dust indicator Check, drain water separator Check coolant level, add coolant Check oil level in power train case, add oil Check electric wiring...
Page 278 MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE DRAIN WATER, SEDIMENT FROM FUEL TANK Carry out this procedure before operating the machine. Prepare a container to catch the fuel that is drained. 1. Open cover (1). 2. Turn drain valve (2) at the bottom of the tank to OPEN position (0) and drain the sediment and water that has accumulated at the tank bottom together with fuel.
Page 279 MAINTENANCE SERVICE PROCEDURE LUBRICATING 1. Lower the blade to the ground, then stop the engine. 2. Only when lubricating the lift cylinder support shaft, lower the blade to raise the idler 1to 2 cm from the ground, then stop the engine. 3.
Page 280 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. Only when lubricating the lift cylinder support shaft, lower the blade to raise the idler 1to 2 cm from the ground, then stop the engine.
Page 281 MAINTENANCE SERVICE PROCEDURE STRAIGHT TILT POWER PITCH DOZER, SIGMA POWER PITCH DOZER (1) Lift cylinder support yoke (4 places) (2) Lift cylinder support shaft (2 places) (3) Lift cylinder ball joint (2 places) (4) Tilt cylinder ball joint (1 place) (5) Pitch cylinder ball joint (1 place) (6) Brace ball joint (2 places) ANGLE DOZER...
Page 282 MAINTENANCE SERVICE PROCEDURE POWER ANGLE POWER TILT DOZER (1) Lift cylinder support yoke (4 places) (2) Lift cylinder support shaft (2 places) (3) Lift cylinder head pin (2 places) (4) Angle cylinder bottom pin (2 place) (5) Angle cylinder head pin (2 place) (6) Tilt cylinder bottom pin (1 places) (7) Tilt cylinder head pin (1 place) 4 - 57...
Page 283 MAINTENANCE SERVICE PROCEDURE GREASE EQUALIZER BAR SIDE PIN Left and right, 1 places each 1. Remove all dirt from the top of the track frame and cover. 2. Clean the grease fitting indicated with the arrow, then supply grease to that fitting with a grease pump. REMARK Supply 3 shots of grease (Operate the grease pump lever 3 times) to each grease fitting, and check that grease is newly...
Page 284 MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this procedure before operating the machine. WARNING Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion. The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near the battery.
Page 285 If distilled water is added to above U.L. line, use a syringe to lower the level to U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 60...
Page 286 Neutralize the removed electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your battery maker. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 287 MAINTENANCE SERVICE PROCEDURE CHECK, CLEAN ADDITIONAL FUEL STRAINER 1. Open cover (1). 2. Turn fuel supply valve (2) to CLOSE position (C), then remove strainer cap (3). The strainer forms 1 unit with the strainer cap. 3. Remove any dirt stuck to the strainer, then wash in clean diesel fuel or flushing oil.
Page 288 SERVICE PROCEDURE CHECK BRAKE PERFORMANCE WARNING If the machine moves during the following operation, contact your Komatsu distributor for repairs immediately. NOTICE Do not place the gear shift lever in 1st under any circumstances. The machine will be damaged. Before starting the engine, check that the area around the machine is safe, then do as follows: 1.
Page 289 MAINTENANCE SERVICE PROCEDURE EVERY 500 HOURS SERVICE Maintenance for every 50 and 250 hours service should be carried out at the same time. REPLACE AIR CONDITIONER FRESH/RECIRC FILTERS REMARK Filtering capability of the filter can lower due to aging, so be sure to replace it with new one once a year. Clean the filter more frequently when the machine is used in a sandy district, bushy or grassy land, etc.
Page 290 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3. Remove external air filter cover (4) and remove external air filter (5). 4. Remove dirt from the seal surface of external air filter cover (4). 5. Install a new external air filter and then install external air filter cover (4).
Page 291 3. Loosen drain plug (P) to drain oil. Do it slowly so that you do not get splashed with drained oil. 4. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 5. Install drain plug (P).
Page 292 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 11. After replacing the filter cartridge, add oil through oil filler (F) until the oil level is between the H and L marks on the dipstick (G). 12. Run the engine at idle for a short time, then stop the engine, and check that the oil level is between the H and L marks on the dipstick.
Page 293 The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 294 MAINTENANCE SERVICE PROCEDURE 9. When installing, bring the packing surface into contact with the seal surface of filter cartridge (4), then tighten it a further 1/4 to 1/2 turns. If the transparent cap is tightened too much, the O-ring may be damaged, and this will cause leakage of fuel. If it is not tightened enough, fuel will leak through the gap at the O-ring.
Page 295 MAINTENANCE SERVICE PROCEDURE Bleed the air as follows: 16. Add fuel to the fuel tank until full (to FULL mark on the fuel gauge). 17. Insert the key in the starting switch and turn the key to the ON position (B). The electric priming pump is actuated.
Page 296 The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 297 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 5. Put a container under filter cartridge (4) to receive drained oil. 6. Using a filter wrench, turn cartridge (4) to the left to remove it. Replace inner seal (5) with a new part. NOTICE Do not fill the new filter cartridge with fuel.
Page 298 MAINTENANCE SERVICE PROCEDURE Bleed the air as follows: 11. Add fuel to the fuel tank until full (to FULL mark on the fuel gauge). 12. Insert the key into the engine starting switch and turn the key to ON position (B). Then the electric priming pump begins to work.
Page 299 MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN PUMP 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 300 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3) Lower and open the cover gradually. (A) Front of machine (B) Dangerous place 4. Loosen mounting bolt (4) of the power train strainer, then remove cover (5). 5. Take out spring (6), then take out strainer (7). 6.
Page 301 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 12. Open the inspection window of the cover on the right side of the machine. 13. Refill the specified quantity of oil through oil filler (F). 14. Check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL (PAGE 3-96)".
Page 302 MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN DAMPER 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. The undercover is heavy. Never try to open or close the cover when directly beneath it.
Page 303 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. If there is still pressure remaining inside the case, the oil or plug may fly out. Loosen the plug slowly to release the pressure.
Page 304 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS Ask your Komatsu distributor to check the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. CHECK FOR LOOSE ROPS MOUNT BOLTS Check that the bolts are not loose and that there is no damage.
Page 305 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 ELEMENT AND CLEAN HYDRAULIC TANK STRAINER WARNING Immediately after the engine is stopped, the parts and the oil are at a high temperature.
Page 306 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 5. Remove bolt (3), then remove cover (4). 6. Take out spring (5), valve (6), and element (7). 7. Clean the inside of the case, then wash spring (5) and valve (6). 8. Install new element (7), valve (6), and spring (5). 9.
Page 307 Do not make holes in it or weld it or gas cut it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Contact your Komatsu distributor to have this work carried out. FUNCTION OF ACCUMULATOR The accumulator (1) stores the pressure in the control circuit.
Page 308 MAINTENANCE SERVICE PROCEDURE CHECKING FUNCTION OF ACCUMULATOR Replace the accumulator every 2 years or every 4000 hours, whichever comes sooner. Check the nitrogen gas charge pressure as follows. 1. Stop the machine on firm, level ground. 2. Operate the parking brake lever to LOCK position (L). 3.
Page 309 If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the machine. In the following cases, the charge pressure of the accumulator has gone down. Please contact your Komatsu distributor.
Page 310 MAINTENANCE SERVICE PROCEDURE METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT NOTICE Finish the steps of operating the blade control lever to the front and back, and to the right and left, to each stroke end within 15 seconds after the engine has stopped. After the engine stops, pressure inside the accumulator begins to gradually go down, so the pressure cannot be released except right after the engine stops.
Page 311 MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN DAMPER CASE WARNING The parts and oil is very hot just after the operation. Wait until the oil temperature drops, then start the work. The undercover is heavy (22 kg (49 lb)). Never try to open or close the cover when directly beneath it.
Page 312 Contact your Komatsu distributor to have the alternator checked. If the engine is started frequently, have this inspection carried out every 1000 hours. CHECK ENGINE VALVE CLEARANCE, ADJUST Special tools are needed for inspection and maintenance, please contact your Komatsu distributor. 4 - 87...
Page 313 If this happens, ask your Komatsu distributor to replace the accumulator. CHECK WATER PUMP Check the water pump and its relative parts for water leak, and if anything abnormal is found, call on your Komatsu distributor for repairs or replacement. CHECK STARTING MOTOR Contact your Komatsu distributor to have the starting motor checked.
Page 314 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER Check clamp (1) visually and touch by hand to check that there are no loose bolts or hardening of the rubber. If there are any loose bolts or hardened rubber, please contact your Komatsu distributor for replacement. NOTICE If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is danger of damage or breakage occurring due to vibration and wear at the connections of high-pressure piping.
Page 315 Check fuel spray prevention caps (1) through (14) visually or with a finger to see if any of them has slipped off, or the rubber portion is hardened. If any such abnormality is found, call on your Komatsu distributor for repairs or replacement.
Page 316 Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Contact your Komatsu distributor to have the engine high-pressure clamps replaced. REPLACE FUEL SPLAY PREVENTION CAPS Contact your Komatsu distributor to have the fuel spray prevention cap replaced. 4 - 91...
Page 318 5 - 1...
Page 319 Sigma dozer dozer 19,430 (42,843) 20,910 (46,107) Machine weight kg (lb) [19,750 (43,549)] [21,230 (46,812)] Name of engine Komatsu SAA6D114E-3 diesel engine Engine rated horsepower (NET) kW{HP}/rpm 153{205}/1,950 Rear work equipment Hitch Counterweight Type, width of shoe mm (ft in) Single, 510 (1' 8")
Page 320 Straight tilt dozer dozer 20,910 (46,107) 21,780 (48,025) Machine weight kg (lb) [21,230 (46,812)] [22,120 (48,775)] Name of engine Komatsu SAA6D114E-3 diesel engine Engine rated horsepower (NET) kW{HP}/rpm 153{205}/1,950 Rear work equipment Hitch Hitch Type, width of shoe mm (ft in) Single, 915 (3' 0")
Page 321 Sigma dozer dozer 20,290 (44,739) 21,810 (48,091) Machine weight kg (lb) [20,610 (45,445)] [22,130 (48,797)] Name of engine Komatsu SAA6D114E-3 diesel engine Engine rated horsepower (NET) kW{HP}/rpm 153{205}/1,950 Rear work equipment Hitch Counterweight Type, width of shoe mm (ft in) Single, 760 (2' 6")
Page 322 6 - 1...
Page 323 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 distributor first.
Page 324 ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER HANDLING HYDRAULIC RIPPER This hydraulic ripper is for D65EX and D65WX dozers. GENERAL VIEW Hydraulic cylider Shank Link Point Beam Support 6 - 3...
Page 325 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 ripper to the ground and set the work equipment lock lever to the LOCK position. This lever is used to operate the ripper.
Page 326 ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER OPERATION CHECK BEFORE STARTING ENGINE, ADJUST WALK-AROUND CHECK 1. Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the rivets. If any problem is found, replace or repair. PRECAUTIONS WHEN OPERATING Travel in low speed and lower the ripper gradually when starting to move the machine off.
Page 327 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER 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). REPLACEMENT OF POINT A point is installed to protect the shank.
Page 328 HANDLING HYDRAULIC RIPPER TROUBLESHOOTING OTHER TROUBLE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Slow ripper raising and function,...
Page 329 ATTACHMENTS, OPTIONS HANDLING 3 M WIDE BLADE HANDLING 3 M WIDE BLADE GENERAL VIEW This blade is applicable for the D65PX and D65WX. Center blade Lock plate Folding blade, left Lock pin Folding blade, right Shim (For offset pin) Offset pin Shim (For hinge pin) Hinge pin (10)
Page 330 ATTACHMENTS, OPTIONS HANDLING 3 M WIDE BLADE OPERATION PROHIBITED OPERATION CAUTION Use the 3 m blade for light dozing work or leveling work. Do not dig hard/frozen ground by using the right and left folding portions of the blade or perform severe work such as stumping, ditching, etc.
Page 331 ATTACHMENTS, OPTIONS HANDLING 3 M WIDE BLADE TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. TRANSPORTATION MEANS As a rule, transport the machine on a trailer. Select a trailer according to the mass and dimensions of the machine shown in "SPECIFICATIONS (PAGE 6-14)". Note that the mass and dimensions for transportation shown in SPECIFICATIONS depend on the types of shoe, blade, etc.
Page 332 ATTACHMENTS, OPTIONS ATTACHMENTS, OPTIONS HANDLING 3 M WIDE BLADE HANDLING 3 M WIDE BLADE 5. Remove lock pins (1) from both ends of folding blade (3). 6. Remove lock plates (2) from right and left folding blades (3). 7. With center pin (4) installed to the center blade, rotate lock plate (2) backward approximately 100 deg.
Page 333 ATTACHMENTS, OPTIONS HANDLING 3 M WIDE BLADE UNFOLDING OF BLADE Unfold the blade in the reverse order to folding. REMARK Install shims (7) above the upper offset pins (5) at the right and left ends of the center blade. 6 - 12...
Page 334 ATTACHMENTS, OPTIONS HANDLING 3 M WIDE BLADE MAINTENANCE WHEN REQUIRED ADJUSTMENT OF PLAY IN BLADE BOSS WARNING It is dangerous that the work equipment starts moving for some reason while you are adjusting the blade. Set the work equipment under a stable condition, stop the engine, and securely set the work equipment lock lever and parking brake lever to their LOCK positions.
Page 335 ATTACHMENTS, OPTIONS HANDLING 3 M WIDE BLADE SPECIFICATIONS Power angle power tilt dozer (Blade width: 3 m) Item Unit D65PX/WX-16 Overall length (When unfolded) mm (ft in) 4,010 (13' 2") Overall length (When folded) mm (ft in) 2,990 (9' 10") Overall blade width (When folded) mm (ft in) 2,960 (9' 9")
Page 336 Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications.
Page 338 INDEX INDEX <A> PRECAUTIONS WHEN GETTING ON ADJUSTING POSTURE OF WORK OR OFF MACHINE 2- 13 EQUIPMENT 3-140 PRECAUTIONS WHEN RUNNING AIR CONDITIONER, HANDLING 3- 76 ENGINE INSIDE BUILDING 2- 17 ASHTRAY 3- 70 PREPARATIONS FOR SAFE OPERATION 2- 10 <B>...
Page 339 4- 12 DURING STORAGE 3-165 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR <M> PRODUCTS OTHER THAN MACHINE MONITOR KOMATSU GENUINE OIL 4- 14 MAINTENANCE SCHEDULE CHART 4- 18 USE OF FUEL, COOLANT AND MAINTENANCE SCHEDULE CHART 4- 18 LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 13 <O>...
Page 340 INDEX TRAVELING ON ROADS 3-162 TROUBLESHOOTING 3-166 AFTER RUNNING OUT OF FUEL 3-166 IF BATTERY IS DISCHARGED 3-168 METHOD OF TOWING MACHINE 3-167 OTHER TROUBLE 3-172 <W> WEAR PARTS LIST 4- 10 WEAR PARTS LIST 4- 10 7 - 3...
Page 341 D65EX-16, D65PX-16, D65WX-16 BULLDOZER Form No. TEN00488-03 © 2013 KOMATSU All Rights Reserved Printed in Japan 05-13...

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