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.
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Page 3: Foreword
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy. When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
Page 4: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Page 5 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
Page 6: Introduction
FOREWORD INTRODUCTION INTRODUCTION 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 3-88)" for further details.
Page 7: Necessary Information
FOREWORD NECESSARY INFORMATION NECESSARY INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is at the front bottom right of the operator's seat. The design of the nameplate differs according to the territory.
Page 8: Position Of Service Meter
FOREWORD NECESSARY INFORMATION POSITION OF SERVICE METER Monitor panel specification This is at the left upper part of the monitor panel. Gauge panel specification The gauge is located on the left lower part of the monitor panel. TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No.
Page 9: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTRODUCTION FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE NECESSARY INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NO. PLATE POSITION OF SERVICE METER TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR SAFETY SAFETY SAFETY LABELS POSITIONS OF SAFETY PICTOGRAMS SAFETY LABELS GENERAL PRECAUTIONS...
Page 10 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 11 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 12 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 13 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 14 TORQUE LIST...
Page 11 FOREWORD CONTENTS EVERY 50 HOURS SERVICE 4- 44 EVERY 250 HOURS SERVICE 4- 45 EVERY 500 HOURS SERVICE 4- 57 EVERY 1000 HOURS SERVICE 4- 60 EVERY 2000 HOURS SERVICE 4- 67 EVERY 4000 HOURS SERVICE 4- 72 SPECIFICATIONS SPECIFICATIONS ATTACHMENTS, OPTIONS GENERAL PRECAUTIONS PRECAUTIONS RELATED TO SAFETY...
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Page 13: Safety
SAFETY SAFETY SAFETY SAFETY LABELS POSITIONS OF SAFETY PICTOGRAMS SAFETY LABELS GENERAL PRECAUTIONS Safety rules If problems are found Clothing and personal protective items Fire extinguisher and first aid kit Safety features Keep machine clean 2- 10 Inside operator's compartment 2- 10 Always apply lock when leaving operator's seat 2- 10...
Page 14 SAFETY SAFETY PRECAUTIONS FOR OPERATION 2- 17 STARTING ENGINE 2- 17 Checks before starting engine 2- 17 Precautions when starting 2- 17 Precautions in cold areas 2- 18 OPERATION 2- 19 Checks before operation 2- 19 Precautions for moving machine forward or in reverse 2- 19 Precautions when traveling 2- 19...
Page 15: Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor. POSITIONS OF SAFETY PICTOGRAMS...
Page 16: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating or maintaining machine (09651-03001) (2) Caution before moving in reverse (09802-13000) (3) Caution for leaving operator's seat (09654-33001) 2 - 5...
Page 17 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 18 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) Precautions when handling ROPS (09620-30201) 2 - 7...
Page 19 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (12) Prohibition of jump start (09842-A0481) (13) Precaution when handling battery (14X-98-11370) 2 - 8...
Page 20: General Precautions
SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions in this manual when operating or performing maintenance on the machine. If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
Page 21: Keep Machine Clean
SAFETY GENERAL PRECAUTIONS KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes.
Page 22: Handrails And Steps
SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps (including the track shoe)
Page 23: Prevention Of Burns
SAFETY GENERAL PRECAUTIONS PREVENTION OF BURNS Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation.
Page 24: Action If Fire Occurs
If ROPS is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the method of repair.
Page 25: Unauthorized Modification
Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 26: Ensure Good Visibility
SAFETY SAFETY SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS GENERAL PRECAUTIONS Even going close to high-voltage cables can cause electric Voltage of Cables Safety Distance shock, which may cause serious burns or even death. Always 100 V - 200 V Over 2 m (7 ft) maintain a safe distance (see the table on the right) between the 6,600 V Over 2 m (7 ft)
Page 27: Be Careful About Asbestos Dust
Do not allow other persons to approach during the operation. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2 - 16...
Page 28: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION STARTING ENGINE If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers. CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.
Page 29: Precautions In Cold Areas
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS IN COLD AREAS Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
Page 30: Operation
SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of travel, steering and brake systems, and work equipment control system.
Page 31: Traveling On Slopes
SAFETY SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION Avoid traveling over obstacles when possible. If the machine has to travel over an obstacle, keep the work equipment close to the ground and travel at low speed. Never travel over obstacles which make the machine tilt strongly to one side. When traveling or carrying out operations, always keep a safe distance from people, structures, or other machines to avoid coming into contact with them.
Page 32: Operate Carefully On Snow
SAFETY PRECAUTIONS FOR OPERATION OPERATE CAREFULLY ON SNOW 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 33: Transportation
PRECAUTIONS FOR OPERATION TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 34: Battery
SAFETY PRECAUTIONS FOR OPERATION BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion.
Page 35: Starting With Booster Cable
SAFETY PRECAUTIONS FOR OPERATION STARTING WITH BOOSTER CABLE If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
Page 36: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING WHEN TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing method, see "MACHINE TOWING METHOD (PAGE 3-111)". Always wear leather gloves when handling wire rope.
Page 37: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG Always attach the "DO NOT OPERATE" warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.
Page 38: Two Workers For Maintenance When Engine Is Running
SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE Set work equipment lock lever (1) and parking brake lever (2) to the LOCK position. Put blocks under the track to prevent the machine from moving. TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running.
Page 39: Proper Tools
Do not make holes in it, weld it, or use a cutting torch. Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed. NO UNAUTHORIZED PERSONNEL INTO AREA Do not allow any unauthorized personnel into the area when servicing the machine.
Page 40: Work Under The Machine
SAFETY PRECAUTIONS FOR MAINTENANCE WORK UNDER THE MACHINE If it is necessary to go under the work equipment or the machine to carry out service and maintenance, support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine.
Page 41: Precautions When Using High-Pressure Grease To Adjust Track Tension
If it is disassembled by mistake, the spring will fly out and cause serious injury. When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work. PRECAUTION WITH HIGH-PRESSURE OIL The hydraulic system is always under internal pressure.
Page 42: Handling High-Pressure Hoses
If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 44 3 - 1...
Page 45: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Machine equipped with cab Machine equipped with canopy Blade Sprocket Tilt cylinder Pivot shaft Radiator mask Track frame Lift cylinder (10) Frame (11) Idler Track shoe (12) Canopy 3 - 2...
Page 46: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Machine equipped with cab Fuel control lever (15) Parking brake lever Cigarette lighter (16) Service meter Joystick (steering, forward-reverse, gear shift (17) Engine coolant temperature gauge lever) (18) Transmission oil temperature gauge Air conditioner panel or heater panel (19) Fuel gauge...
Page 47 OPERATION GENERAL VIEW Machines equipped with canopy Monitor panel specification Fuel control lever (13) Parking brake lever Joystick (steering, forward-reverse, gear shift (14) Service meter lever) (15) Engine coolant temperature gauge Head lamp switch (16) Transmission oil temperature gauge Rear lamp switch (17) Fuel gauge Glow switch...
Page 48: Fuel Control Lever
OPERATION GENERAL VIEW Machines equipped with canopy Gauge panel specification Fuel control lever (10) Horn switch Joystick (steering, forward-reverse, gear shift (11) Work equipment lock lever lever) (12) Parking brake lever Head lamp switch (13) Engine coolant temperature gauge Rear lamp switch (14) Transmission oil temperature gauge Speed range display lamp...
Page 49: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MONITOR PANEL MONITOR PANEL (Monitor panel specification)
Page 50: Engine Coolant Temperature Gauge
OPERATION EXPLANATION OF COMPONENTS ENGINE COOLANT TEMPERATURE GAUGE This gauge (2) indicates the coolant temperature. When the indicator is in the white range during operation, the coolant temperature is normal. If the indicator moves from the white range into the red range during operation, stop the machine immediately, run the engine under no load at a midrange speed, and wait for the indicator to go down to the white range.
Page 51: Charge Lamp
OPERATION EXPLANATION OF COMPONENTS CHARGE LAMP This lamp (6) indicates malfunction of the alternator. When the starting switch is turned ON, it will light up, but it should go out when the engine speed rises. If the lamp lights up during operation, stop the engine and check the V-belt tension.
Page 52 OPERATION EXPLANATION OF COMPONENTS MONITOR CAUTION LAMP This lamp (10) lights up when any of the following caution lamps lights up. In addition, the alarm buzzer sounds at the same time. Engine coolant temperature caution lamp (5) Charge lamp (6) Engine oil pressure caution lamp (7) Transmission oil temperature caution lamp (9) MONITOR CAUTION CANCELLATION SWITCH...
Page 53: Gauge Panel
OPERATION EXPLANATION OF COMPONENTS GAUGE PANEL (Gauge panel specification) Service meter Charge lamp Engine coolant temperature gauge Engine oil pressure caution lamp Transmission oil temperature gauge Glow signal SERVICE METER This meter (1) shows the total number of hours the machine has operated.
Page 54: Glow Signal
OPERATION EXPLANATION OF COMPONENTS TRANSMISSION OIL TEMPERATURE GAUGE This meter (3) shows transmission lubrication oil temperature.The temperature is normal, if the needle remains in the green range while in operation. If the needle goes into the red range while operating, stop the machine and let the engine idle with middle rpm and wait until the needle drops to the green range.
Page 55: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Machine equipped with cab Machine equipped with canopy Starting switch Additional working lamp switch Glow switch (machine equipped with cab) (if equipped) Horn switch Wiper switch (machine equipped with cab) Head lamp switch Room lamp switch (machine equipped with cab) Rear lamp switch Cigarette lighter (machine equipped with cab) 3 - 12...
Page 56: Starting Switch
OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH This switch (1) is used to start or stop the engine. OFF Position At this position, the starting switch key can be inserted or removed. When the switch is turned to this position, all the electric circuits are turned off and the engine stops.
Page 57: Horn Switch
OPERATION EXPLANATION OF COMPONENTS GLOW SWITCH (Monitor panel specification) This switch (2) actuates the electrical heater to warm up the engine intake air. OFF position: The preheating is not actuated. AUTO position: AUTO preheating is actuated. The length of the preheating time varies according to the ambient temperature when the ambient temperature is below approx.
Page 58: Rear Lamp Switch
OPERATION EXPLANATION OF COMPONENTS REAR LAMP SWITCH This switch (5) lights up the rear lamps. OFF position: Lamps are out ON position: Lamps light up ADDITIONAL WORKING LAMP SWITCH (Machine equipped with cab) (If equipped) This switch (6) is used to turn on the additional working lamp. (A) Head lamp switch (B) Rear lamp switch Push in the direction of the arrow to turn on the lamps.
Page 59 OPERATION EXPLANATION OF COMPONENTS WIPER SWITCH (Machine equipped with cab) This switch (7) activates the wipers. The wiper switches are as follows. (A) L.H. door (B) Front window (C) R.H. door (D) Rear window This is also used as the window washer switch. The switch is operated as follows.
Page 60: Cigarette Lighter
OPERATION EXPLANATION OF COMPONENTS ROOM LAMP SWITCH (Machine equipped with cab) This lamp is used to turn on and off room lamp (8). ON position: Lamp lights up OFF position: Lamp is out CIGARETTE LIGHTER (Machine equipped with cab) This lighter (9) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after a few seconds, so take it out to light your cigarette.
Page 61: Lamp
OPERATION EXPLANATION OF COMPONENTS LAMP Machine equipped with cab. Following illustration shows machine equipped with air conditioner. Machine equipped with canopy Speed range display lamp SPEED RANGE DISPLAY LAMP This lamp (1) indicates the currently selected gear speed range. When lamp 1 lights up: 1st When lamp 2 lights up: 2nd When lamp 3 lights up: 3rd...
Page 62: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS Work equipment lock lever Brake pedal Parking brake lever Decelerator pedal Fuel control lever Blade control lever Steering, forward-reverse, gear shift lever WORK EQUIPMENT LOCK LEVER WARNING When leaving the operator's compartment, set the work equipment lock lever securely to the LOCK position. If the work equipment lock lever is not at the LOCK position and the control levers are touched by mistake, it may lead to serious personal injury.
Page 63: Parking Brake Lever
OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE LEVER WARNING When parking the machine, always set the parking brake lever in the LOCK position. If the parking brake lever is operated, the brake is applied, even when the machine is traveling. The machine will suddenly stop, so this is dangerous. For this reason, do not operate the parking brake lever when the machine is moving, except in emergencies.
Page 64 OPERATION EXPLANATION OF COMPONENTS STEERING, FORWARD-REVERSE, GEAR SHIFT LEVER This lever (4) is used to select the direction of travel, to shift gear, and to steer the machine. Forward-reverse shifting Position (a): FORWARD Position (b): REVERSE Position N: NEUTRAL Steering Position (c): LEFT TURN Position (d): RIGHT TURN If the lever is set in the forward or reverse travel position and...
Page 65: Brake Pedal
OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING Do not place your foot on this pedal unnecessarily. If this pedal (5) is depressed, the left and right brakes are applied simultaneously. DECELERATOR PEDAL WARNING Do not place your foot on this pedal unnecessarily. When passing over the top of a hill or when a load is dumped over a cliff, the load is suddenly reduced, so there is danger that the travel speed will also increase suddenly.
Page 66: Blade Control Lever
OPERATION EXPLANATION OF COMPONENTS BLADE CONTROL LEVER POWER TILTDOZER This lever (7) is used to lift or tilt the blade. Lifting control (a) RAISE: (b) HOLD: Blade is stopped and held in this position. (c) LOWER: (d) FLOAT: Blade will move freely according to external force. REMARK When the control lever is at the FLOAT position and it is released, it does not automatically return to HOLD, so return it...
Page 67 OPERATION EXPLANATION OF COMPONENTS POWERTILT POWER PITCHDOZER This lever (7) is used to lift or tilt and pitch the blade. Lifting control (a) RAISE: (b) HOLD: Blade is stopped and held in this position. (c) LOWER: (d) FLOAT: Blade will move freely according to external force. REMARK When the control lever is at the FLOAT position and it is released, it does not automatically return to HOLD, so return it...
Page 68 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Pitch control First set the lever to the neutral position, then keep switch (A) in the center of the knod pushed down and carry out the tilt operation to change the cutting angle of the blade. (b) HOLD: Blade is stopped and held in this position.
Page 69 OPERATION EXPLANATION OF COMPONENTS ANGLE DOZER This lever (7) is used to raise the blade. Lifting control (a) RAISE: (b) HOLD: Blade is stopped and held in this position. (c) LOWER: (d) FLOAT: Blade will move freely according to external force. REMARK When the control lever is at the FLOAT position and it is released, it does not automatically return to HOLD, so return it...
Page 70: Fuse
OPERATION EXPLANATION OF COMPONENTS FUSE NOTICE Before replacing a fuse, be sure to turn starting switch to the OFF position. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse. Replace the fuse with another of the same capacity.
Page 71 OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITY AND CIRCUIT NAME Fuse box (1) Fuse Circuit Name Capacity Front lamp, rear working lamp Chassis power source Engine control system Horn Backup alarm Fuse box (2) Fuse Circuit Name Capacity Cab radio Power pitch switching Air Conditioner Spare power source Chassis power source...
Page 72: Electric Power Take-Out Adapter
OPERATION EXPLANATION OF COMPONENTS ELECTRIC POWER TAKE-OUT ADAPTER NOTICE Do not use as a power supply for 12V equipment. This will cause failure of the equipment. When using as a power supply pickup, do not install equipment which exceeds 120W (24V x 5A). 1.
Page 73: Door - Open Lock
OPERATION EXPLANATION OF COMPONENTS DOOR - OPEN LOCK (Machine equipped with cab) Use this when your want to keep the door held open. 1. Push the door against the door catch (1). The door will be held by the door catch. 2.
Page 74: Cap, Cover With Lock
OPERATION EXPLANATION OF COMPONENTS CAP, COVER WITH LOCK Use the starting switch key to open and close the caps and covers. For their locations , see "LOCKING (PAGE 3-97)". Insert the key as far as it will go to the shoulder. If the key is turned before it is inserted all the way, it may break.
Page 75: Hot And Cool Box
OPERATION EXPLANATION OF COMPONENTS METHOD OF OPENING AND CLOSING COVER WITH LOCK TO OPEN THE COVER (LOCKED COVER) 1. Insert the key into the key slot. 2. Turn the key counterclockwise and open the cover by pulling the cover grip. TO LOCK THE COVER 1.
Page 76: Ashtray
OPERATION EXPLANATION OF COMPONENTS Machine not equipment with cab There is a pocket on the back of the operator's seat. Keep the Operation & Maintenance manual in this pocket so that the operator can read it whenever necessary. ASHTRAY (Machine equipped with cab) This is on the left side of the operator's seat.
Page 77: Air Conditioner, Handling
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER, HANDLING (Machine equipped with cab) EXPLANATION OF PARTS FRESH/RECIRC selector lever Blower switch Air conditioner switch Temperature control lever FRESH/RECIRC SELECTOR LEVER This lever (1) changes the air intake port used when cooling or heating.
Page 78: Blower Switch
OPERATION EXPLANATION OF COMPONENTS BLOWER SWITCH This switch (3) acts as the wind flow control switch and main switch when cooling or heating. The air flow can be set to three stages: 1 (LOW) 2 (MEDIUM) 3 (HIGH). If the switch is set to 0, the power is switched off and the air conditioner stops.
Page 79: Cooling Operation
OPERATION EXPLANATION OF COMPONENTS COOLING OPERATION When the cooling operation is carried out, the inside of the cab is cooled, and at the same time the drinks inside the hot and cool box can be cooled. COOLING (RECIRC) When the control switch and lever are operated as shown in the diagram, a cool breeze is sent out.
Page 80: Heating Operation
OPERATION EXPLANATION OF COMPONENTS HEATING OPERATION When the heating operation is carried out, the inside of the cab is heated, and at the same time the drinks inside the hot and cool box can be heated. HEATING (RECIRC) When the control switch and lever are operated as shown in the diagram, warm air is sent out.
Page 81 OPERATION EXPLANATION OF COMPONENTS PREVENTION METHOD OF ENTRY OF DUST Entry of dust into the cab can be prevented by starting the blower fan for the air conditioner to raise the pressure in the cab a little higher than outside. When working in a dusty job site or when preventing dust from entering the cab, use this function.
Page 82: Cleaning Air Filter
OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR REPLACING RECEIVER Replace the receiver once every 2 years. After replacing the receiver, add compressor oil. Turn the receiver at an angle and measure the oil remaining inside the receiver, then add the same amount of oil (Denso Oil 6) to fill the receiver. REMARK Depending on the condition of use, the replacement interval may be shorter.
Page 83: Handling Heater
OPERATION EXPLANATION OF COMPONENTS HANDLING HEATER (Machine equipped with cab) EXPLANATION OF PARTS FRESH/RECIRC selector lever Temperature control lever Blower switch FRESH/RECIRC SELECTOR LEVER This lever (1) changes the air intake port used when cooling or heating. RECIRC: If lever (1) is shifted to the left, the air conditioner sucks inside air.
Page 84: Method Of Operation
OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL LEVER This lever (3) is used to control the temperature for heating. When the temperature control lever is moved to the right, the temperature of the air coming from the vents becomes lower. When the temperature control lever is moved to the left, the temperature of the air coming from the vents becomes higher.
Page 85 OPERATION EXPLANATION OF COMPONENTS CLEANING AIR FILTER If the air filter for the FRESH or RECIRC air intake becomes clogged, the cooling or heating capacity will drop. In places where there is a lot of dust, clean the air with compressed air once a week. For details of the cleaning method, see "CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (PAGE 4-56)".
Page 86: Operation
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor. Do not get on or off the machine from the rear. Using this position is dangerous because it is easy to slip and you cannot be seen from the operator's compartment.
Page 87 OPERATION OPERATION 8. Seat belt and mounting clamps Check for damage or wear to the seat belt and mounting clamps. If there is any damage, replace with new parts. CHECK BEFORE STARTING Always check the items in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary.
Page 88 2 seconds, and the alarm buzzer sounds for 1 second. REMARK If the lamps do not light up, there may be a failure or disconnection in the monitor, please contact your Komatsu distributor. 3 - 45...
Page 89 If any lamp does not light up or two or more lamps light up, or if the lighting lamp does not change even the gear is shifted, the gear speed lamp system or its wire may be broken. In this case, call your Komatsu distributor and ask for inspection. 3 - 46...
Page 90 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 91 OPERATION OPERATION GAUGE PANEL SPEC 1. Remove the cap and check the fuel level using fuel gauge (G). 2. After completing work, fill the fuel tank through fuel filler port (F). Fuel capacity: 410 liters (108.32 US gal) 3. After adding fuel, tighten the cap securely. REMARK When dozing on a grade, make sure there is plenty of fuel in the tank so that the engine fuel line does not become aerated.
Page 92 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 93 2. The distance of travel at the center of the pedal should be 70 to 90 mm (2.8 to 3.5 in). 3. When this value exceeds 91 mm (3.6 in), or the brake fails to work, please contact your Komatsu distributor for adjustment. 3 - 50...
Page 94 If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately perform repairs, or contact your Komatsu distributor for repairs. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clean the breather hole.
Page 95 Check that the head lamp, rear lamp, additional working lamp (if equipped), and instrument lamp light up normally and they are free from stain and damage. If the lamps do not light, check for a broken bulb or disconected wire, contact your Komatsu distributor for repairs. 1. Turn the starting switch to the ON position.
Page 96 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 the starting switch to the ON position.
Page 97 OPERATION CHECK OF OPERATION OF BACKUP ALARM Check that the backup alarm sounds normally. If it does not, a defect or broken wire is suspected, ask your Komatsu distributor for possible repairs. 1. Turn the starting switch to the ON position.
Page 98 OPERATION OPERATION CHECK, CLEAN WATER SEPARATOR (If equipped) The water separator separates water mixed in the fuel. If float (2) is at or above red line (1), drain the water according to the following procedure. 1. Loosen drain plug (3) and drain the accumulated water until the float (2) reaches the bottom.
Page 99 OPERATION OPERATION ADJUSTMENT ADJUST OPERATOR'S SEAT WARNING When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to prevent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 100 OPERATION OPERATION (E) Seat height adjustment Pull up levers (4) and (5) alternately to adjust the angle of the seat. Then, release the levers to lock the seat. (Height adjustment distance: 5 stages, 60 mm (2.4 in)) ADJUST ARMREST The height of the armrests on both sides of the operator's seat can be adjusted to three levels.
Page 101 OPERATION OPERATION FASTENING AND REMOVING SEAT BELT Always install a seat belt on machines equipped with ROPS. WARNING Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there is any wear or damage, replace.
Page 102 OPERATION OPERATION OPERATION AND CHECK BEFORE STARTING ENGINE WARNING When starting the engine, check that the parking brake lever and work equipment lock lever are placed securely at the LOCK position. If the work equipment control lever is touched by accident when the engine is started, the work equipment may move unexpectedly and cause serious injury or damage.
Page 103 OPERATION OPERATION OPERATION OPERATION 2. Insert the key into starting switch (2) and turn the key to the ON position. 3. Check that speed range display lamp (3) shows 1st. 4. Check that steerling, forward-reverse, gear shift lever (4) is at the N (neutral) position.
Page 104: Starting Engine
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 105 OPERATION OPERATION OPERATION OPERATION 4. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position. 5. Continue to run the engine at idling for 15 seconds after starting. During this time, do not operate the control levers or fuel control lever. 3 - 62...
Page 106: Starting In Cold Weather
OPERATION OPERATION 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. Such an act may cause a serious bodily injury or fire.
Page 107 OPERATION OPERATION OPERATION OPERATION 1. Before starting the engine, check that fuel control lever (1) is at the low idling position. 2. Pull fuel control lever (1) to a position midway between the low idling and full speed positions. 3. Insert the key into starting switch (2) and turn the key to the ON position.
Page 108: Automatic Preheating
OPERATION OPERATION AUTOMATIC PREHEATING 1. Turn glow switch (3) to the AUTO position. When it is turned to the AUTO position, preheating is automatically carried according ambient temperature. Lamp (4) lights up during the preheating operation. When the preheating is completed, lamp (4) will go out.
Page 109 OPERATION OPERATION MANUAL PREHEATING 1. Turn glow switch (3) to position I or II. Lamp (4) lights up during the preheating operation. When the preheating is completed, release the switch. The key will then return automatically to the following position. From position I, it will return to AUTO From position II, it will return to OFF The pre-heating times are as shown below.
Page 110 OPERATION OPERATION GAUGE PANEL SPEC NOTICE Do not start the engine with the fuel control lever near the FULL position. It may lead to damage of the engine parts. Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 111 OPERATION OPERATION If the preheating time is too long or too short, the engine will not start easily. Observe the correct preheating time. 4. When glow signal becomes red, turn the starting switch key (2) to the START position to start the engine. 5.
Page 112: Operations And Checks After Starting Engine
BREAKING IN THE NEW MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
Page 113 Continue to run the engine at low load until engine water temperature gauge (2) falls within the white range (Monitor Panel Spec.) or green range (Gauge Panel Spec.). 3. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 70...
Page 114 OPERATION OPERATION STARTING IN COLD WEATHER (Ambient temperature below 10°C (50°F)) After the engine starts, do not start operating the machine immediately. First, carry out the following operations and checks. NOTICE When the hydraulic oil is at low temperature, do not carry out operations or move the levers suddenly.
Page 115 Continue to run the engine at low load until engine water temperature gauge (2) falls within the white range (Monitor Panel Spec.) or green range (Gauge Panel Spec.). 7. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 72...
Page 116: Stopping Engine
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 117 OPERATION OPERATION OPERATION OPERATION 4. Turn the key in starting switch (2) to the OFF position and remove the key from starting switch (2). 3 - 74...
Page 118: Machine Operation
OPERATION OPERATION MACHINE OPERATION MOVING MACHINE WARNING Before moving the machine off, check that the area around the machine is a safe, then sound the horn when moving the machine off. Do not allow anybody to enter the area around the machine. The area behind the machine is a blind spot, so be particularly careful when driving in reverse.
Page 119 OPERATION OPERATION OPERATION OPERATION 2. Operate joystick (4) to the desired position, and check that speed range display lamp (3) shows the correct position. 3. Set the work equipment lock lever (6) to the FREE position. 4. Put blade control lever (5) in the RAISE position to raise the blade 40 to 50 cm (16 to 20 in) off the ground.
Page 120: Stopping Machine
OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. 1. Depress brake pedal (1) to stop the machine. NOTICE If the brake is depressed when the engine speed or travel speed is high, the brake disc may make a slipping sound. Normally, depress decelerator pedal to reduce the engine speed and travel speed before depressing the brake.
Page 121 OPERATION OPERATION OPERATION OPERATION 3. Operate joystick (2) to 1st, and check that speed range display lamp (3) shows the correct position. 3 - 78...
Page 122: Shifting Gears
OPERATION OPERATION SHIFTING GEARS The machine does not have to be stopped to shift gears. 1. Operate joystick (1) to the desired position. Gear shifting Rotate joystick 30° to carry out gear shifting operation. Position (a): 1st gear Position (b): 2nd gear Position (c): 3rd gear For the maximum travel speed in each gear speed, see "SPECIFICATIONS (PAGE 5-2)".
Page 123: Shifting Between Forward And Reverse
OPERATION OPERATION SHIFTING BETWEEN FORWARD AND REVERSE CAUTION The travel direction can be changed without stopping the machine. Do not change it while the engine is running at the full speed, however, but depress the decelerator pedal to lower the engine speed before changing the travel direction for safety, comfort, and longer life of the power train.
Page 124 5. Pull fuel control lever (1) or release decelerator pedal (2) to raise the engine speed. REMARK For machines equipped with a backup alarm, check that the backup alarm sounds when joystick is placed in REVERSE. If the alarm does not sound, please contact your Komatsu distributor. 3 - 81...
Page 125: Steering Machine
OPERATION OPERATION STEERING MACHINE WARNING Avoid as much as possible turning the machine on a slope. The machine will tend to slip sideways. Particular care should be taken on soft or clay land. Never try to turn the machine sharply when traveling at high speed. NORMAL TURNING turn machine...
Page 126 OPERATION OPERATION TURNING LEFT WHILE TRAVELING FORWARD When steering, forward-reverse, gear shift lever (1) is operated to FORWARD and then half way to the left, the steering clutch is disengaged and the machine turns gradually to the left. REMARK To travel forward and turn gradually to the right, operate steering, forward-reverse, gear shift lever (1) to FORWARD and then move it half way to the right.
Page 127 OPERATION OPERATION TURNING WHILE DESCENDING A SLOPE WARNING Run the engine at low speed. In addition, when moving very small distances, use the inching panel. When traveling on slopes, the brake can be used even when the inching panel is being depressed, but always depress the brake with your right foot and take care to prevent the machine from falling.
Page 128 OPERATION OPERATION WHEN TURNING TO THE LEFT SHARPLY WHILE TRAVELING FORWARD If the steering, forward-reverse, gear shift lever (1) is pushed forward and moved fully to the left (L), the machine turns sharply to the left. (Does not become cross steering) REMARK When making sharp turns to the right, push the steering, forward-reverse, gear shift lever (1) forward, and move it fully to the...
Page 129: Precautions For Operation
OPERATION OPERATION PRECAUTIONS FOR OPERATION PAY ATTENTION TO GAUGES If the transmission oil temperature gauge enters the red range during operations, 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 130 OPERATION OPERATION METHOD OF USING BRAKES The following actions cause premature damage to the brakes, so avoid such operations. Using emergency brake at full speed Using brake with engine running at full speed in first gear (F1, R1) (Machine stall condition) REMARK Always depress the decelerator pedal to lower the engine speed before actuating the brakes.
Page 131: Work Possible Using Bulldozer
OPERATION OPERATION WORK POSSIBLE USING BULLDOZER In addition to the following, it is possible to further increase the range of applications by using various attachments. DOZING A bulldozer digs and transports dirt in a forward direction. Slope excavation can always be most effectively carried out by proceeding from the top downward.
Page 132 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 133: Adjusting Posture Of Work Equipment
OPERATION OPERATION ADJUSTING POSTURE OF WORK EQUIPMENT METHOD OF ANGLING BLADE Angledozers only When dozing toward one side only, operate with angled blade. WARNING 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 134 OPERATION OPERATION OPERATION OPERATION 3. Insert arm (2) into the desired position on the bracket on top of the frame (3 places on each side), and insert pins (1). ADJUST AMOUNT OF TILT Angledozers only WARNING When adjusting the amount of tilt, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the work equipment lock lever.
Page 135 OPERATION OPERATION ADJUST ANGLE OF BLADE EDGE (Power tilt dozer) 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. Adjust the angle (θ) of the blade edge to match the type of soil.
Page 136 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 137: Parking Machine
OPERATION OPERATION PARKING MACHINE WARNING When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, place the parking brake lever in the LOCK position and insert blocks underneath the track shoes.
Page 138 OPERATION OPERATION OPERATION OPERATION 3. Move blade control lever (2) to the LOWER position, and lower the blade to the ground. 4. Set the work equipment lock lever (3) in the LOCK position. 3 - 95...
Page 139: Check After Finishing Work
OPERATION OPERATION CHECK AFTER FINISHING WORK BEFORE STOPPING ENGINE Use the meters and caution lamps to check the engine coolant temperature, engine oil pressure, fuel level, and transmission oil temperature. 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 140: Locking
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) (machines equipped with cab) Fuel tank filler cap (6)
Page 141: Tips For Longer Undercarriage Life
OPERATION METHOD Select the track shoe that best suits the type of soil to be encountered in service. Please consult your Komatsu distributor when selecting track shoes. Do not allow shoe slipping to occur during operation. If shoe slipping occurs, reduce load on the blade until slipping stops.
Page 142: Inspection And Repair
Frequent inspection and prompt repair will reduce repair costs. The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Perform periodical inspection and contact the Komatsu distributor in your area when machine has approached repairable limits and reversing limits.
Page 143 OPERATION OPERATION MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 1. Measure the height (dimension C) of the link tread as shown in the diagram. 2. Stop machine at position where link tread, whose size C has been measured completely, contacts roller tread. Then measure size B.
Page 144: Transportation
If it is necessary to remove the cab for transportation, there is danger that the seal may be damaged when removing or installing the cab, so please contact your Komatsu distributor. When installing the cab, please contact your Komatsu distributor, too.
Page 145: Precautions When Removing Work Equipment
OPERATION TRANSPORTATION PRECAUTIONS WHEN REMOVING WORK EQUIPMENT If there is any pressure remaining in the tilt piping after the work equipment has been removed, it may be difficult to remove the quick coupler of the tilt hose, so remove the work equipment as follows. 1.
Page 146: Loading, Unloading Work
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° or less. If the ramps are deflected appreciably, reinforce them with blocks.
Page 147: Securing Machine
OPERATION TRANSPORTATION SECURING MACHINE WARNING When the edge of the blade protrudes beyond the trailer, angle the blade. (Angledozer) NOTICE Be sure to retract the car radio antenna (if the machine equipped with cab). Load the machine onto a trailer as follows: 1.
Page 148 OPERATION TRANSPORTATION UNLOADING WORK 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Make the slope of the ramps a maximum of 15°.
Page 149: Lifting Machine
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, please consult your Komatsu distributor. For weight, see "SPECIFICATIONS (PAGE 5-2)".
Page 150 OPERATION TRANSPORTATION For machine equipped with ripper When lifting the machine, stop it on a level place, then observe the following procedure. 1. Stop the engine and set the parking brake lever to the LOCK position. 2. Install wire ropes, slings, etc. matched to the weight of the machine to the lifting points as shown in the above figure.
Page 151: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 152: After Completion Of Work
OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 153: Long-Term Storage
For machines equipped with an air conditioner, run the air conditioner. 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 154: Troubleshooting
OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When restarting the machine after running out of fuel, fill with fuel and bleed the air from the fuel system before starting. For details of bleeding the air, see "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-57)". MACHINE TOWING METHOD WARNING Be sure to use a wire rope sufficiently strong for the towing weight.
Page 155: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 156 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 3-112)" 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 157: Starting Engine With Booster Cable
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 158 OPERATION TROUBLESHOOTING STARTING ENGINE WARNING Always check that the work equipment lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are in the HOLD or NEUTRAL position. 1.
Page 159: Other Trouble
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 cause Remedy Lamp does not glow brightly even...
Page 160 OPERATION TROUBLESHOOTING Problem Main cause Remedy Speed range display lamp does not Defective wiring ( Check, repair) change when gear is shifted Defective limit switch ( Replace) Blade does not pitch when pitch is Defective wiring ( Check, repair) operated Defective switch ( Replace) (pitch specification only)
Page 161 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 When brake pedal is depress,...
Page 162 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 Engine oil pressure caution lamp Engine oil pan oil level is low Add oil to specified level.
Page 163 OPERATION TROUBLESHOOTING Problem Main causes Remedy Abnormal noise is generated Low grade fuel being used Change to specified fuel (combustion or mechanical) Overheating See item "Indicator of coolant temperature gauge is in red range on right side of gauge" Damage inside muffler ( Replace muffler) Excessive valve clearance ( Adjust valve clearance)
Page 164 4 - 1...
Page 165: Guide To Maintenance
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 166 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 167 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 168: Outline Of Service
Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil. 4 - 5...
Page 169: Coolant And Water For Dilution
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 170: Storing Oil And Fuel
Perform sampling at regular fixed intervals. Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. STORING OIL AND FUEL Keep indoors to prevent any water, dirt, or other impurities from getting in.
Page 171: Relating To Electric System
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. 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 172: Wear Parts List
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. 4 - 9...
Page 173 MAINTENANCE WEAR PARTS LIST WEAR PARTS LIST The parts in parentheses are to be replaced at the same time. Weight Replacement Item Part No. Part Name Q'ty [kg (lb)] frequency 07063-01054 Element Every 250 Power train filter (07000-72100) (O-ring) hours service Fuel filter 600-311-8293 Cartridge Engine oil filter...
Page 174: Recommended Fuel, Coolant, And Lubricant
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 175: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4 - 12...
Page 176: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS ( High-Temperature High-Shear Viscosity 150°C) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most suitable oils. If these oils are not available, follow the instruction "RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL (PAGE 4-13)"...
Page 177: Standard Tightening Torques For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 178: Periodic Replacement Of Safety Critical Parts
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose clamps and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the critical parts. SAFETY CRITICAL PARTS Safety critical parts for periodic replacement...
Page 179: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4- 18 CLEAN INSIDE OF COOLING SYSTEM 4- 21 CHECK TRACK TENSION 4- 24 CHECK AND TIGHTEN TRACK SHOE BOLTS 4- 26 CHECK ELECTRICAL INTAKE AIR HEATER 4- 26 REVERSE AND REPLACE END BITS AND CUTTING EDGES...
Page 180 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 1000 HOURS SERVICE CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING PUMP STRAINER) 4- 60 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 4- 62 CHANGE OIL IN FINAL DRIVE CASE 4- 63 CLEAN BREATHER 4- 63...
Page 181: Service Procedure
MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 182 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 5. Direct dry compressed air (Max. 0.69 MPa (7 kg/cm , 99.4 PSI)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside.
Page 183 MAINTENANCE SERVICE PROCEDURE REPLACING ELEMENT 1. Open the left engine side cover. 2. Loosen bolt (2), remove cover (3). 3. Remove the wing nut (4) and the seal washer (5), and take out the outer element (6). 4. Remove the snap ring (7), nut (8) and washer (9), and then take out the inner element (10).
Page 184: Clean Inside Of Cooling System
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Page 185 MAINTENANCE SERVICE PROCEDURE When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table given below. It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio. The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/total amount of coolant x 100).
Page 186 MAINTENANCE SERVICE PROCEDURE 8. Replace the corrosion resistor, then open 2 valves. For details of the procedure for replacing the corrosion resistor, see "REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-66)". 9. Close drain valve (2), (3). 10. Add coolant mixed with antifreeze until it overflows from the water filler. Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze.
Page 187 Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened with the procedure given here, please contact your Komatsu distributor. WHEN INCREASING TENSION Prepare a grease pump.
Page 188 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor. 1. Loosen plug (1) gradually to release the grease.
Page 189: Check And Tighten Track Shoe Bolts
Tighten the bolts in the order shown in the diagram on the right. CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections.
Page 190: Reverse And Replace End Bits And Cutting Edges
MAINTENANCE SERVICE PROCEDURE REVERSE AND REPLACE END BITS AND CUTTING EDGES WARNING It is dangerous if the work equipment moves by mistake when the cutting edges and end bits are being reversed or replaced. Set the work equipment in a stable condition, then stop the engine and lock the blade control lever securely with the work equipment lock lever.
Page 191 MAINTENANCE SERVICE PROCEDURE REMARK If the cutting edge and the end bit on both sides are worn out, replace with new ones. If it has been worn out up to the fitting surface, repair the fitting surface and then reverse or replace. 4.
Page 192: Clean, Check Radiator Fins
MAINTENANCE SERVICE PROCEDURE CLEAN, CHECK RADIATOR FINS If the radiator fins are clogged or dirty, clean and inspect them. CLEANING WITH COMPRESSED AIR WARNING Directing compressed air, pressurized water, or steam directly at your body, or using these and causing dust to fly may cause personal injury.
Page 193: Check, Adjust Air Conditioner
MAINTENANCE SERVICE PROCEDURE CHECK, ADJUST AIR CONDITIONER (Machine equipped with cab) CHECKING TENSION OF COMPRESSOR BELT If the belt is loose, it will slip and the cooling effect will be reduced. From time to time, press a point midway between the drive pulley and compressor pulley with your finger (approx.
Page 194: Grease Door Hinge
MAINTENANCE SERVICE PROCEDURE GREASE DOOR HINGE (Machine equipped with cab) If the door makes a squeaking noise when it is opened or closed, spray lubricant in through the split in the hinge bushing. If the bushing is worn, replace the hinge. CHECK DOOR LOCK STRIKER (Machine equipped with cab) If the wear of the door lock striker exceeds 0.5 mm (0.02 in),...
Page 195: Check Door Latch
MAINTENANCE SERVICE PROCEDURE CHECK DOOR LATCH (Machine equipped with cab) Hold the door open and check that there is still grease inside the latch. If the amount of grease is low or there is no more grease, coat the inside of the latch with grease from portion (1). REMARK If there is no more grease inside the latch, the movement will become poor because of dust inside the latch, and the handle may...
Page 196: Replace Wiper Blade
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 AND REAR WIPERS 1. Remove screw (1), then remove the blade. 2. Install a new blade, then tighten screw (1) securely. DOOR WIPER 1.
Page 197: Adjust Idler Clearance
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 198: Procedure For Bleeding Air In Hydraulic System
MAINTENANCE SERVICE PROCEDURE PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM See "STARTING ENGINE (PAGE 3-61)". 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 199: Adjusting Shims, Adjusting Tension At Work Equipment Links
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 200 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 201 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 - 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 202 MAINTENANCE SERVICE PROCEDURE ADJUSTING SHIMS AT LIFT CYLINDER HEAD Correct value for play at ball joint: 0.2 - 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 203 MAINTENANCE SERVICE PROCEDURE ADJUSTING SHIMS AT CENTER BRACE Correct value for play at ball joint: 0.2 - 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 204 MAINTENANCE SERVICE PROCEDURE ADJUSTING SHIMS AT TRUNNION Correct value for play at ball joint: 0.2 - 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 205 MAINTENANCE SERVICE PROCEDURE ADJUSTING TENSION OF CENTER BRACE (Power tilt dozer) (Powertilt, Power pitch dozer) (Semi-U 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 206: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-44)" in the OPERATION section. Check coolant level, add coolant Checking with machine monitor Check speed range display lamp Check fuel level, add fuel Check oil level in engine oil pan, add oil Check oil level in power train case, add oil Check brake pedal travel...
Page 207: Every 50 Hours Service
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 drain valve (1) at the bottom inside the inspection cover on the left side at the rear of the machine and drain the water and sediment accumulated at the bottom together with fuel.
Page 208: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATING 1. Lower the blade to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3.
Page 209 MAINTENANCE SERVICE PROCEDURE POWER TILT-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 (1) Lift cylinder support yoke (4 places)
Page 210: Grease Equalizer Bar Side Pin
MAINTENANCE SERVICE PROCEDURE GREASE EQUALIZER BAR SIDE PIN Left and right, 2 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 211: Check Oil Level In Hydraulic Tank, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 212: Check Level Of Battery Electrolyte
If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4 - 49...
Page 213 If water is added to above the bottom tip of the sleeve, use a pipette to remove electrolyte. 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 214: Drain Water, Sediment From Fuel Filter
MAINTENANCE SERVICE PROCEDURE DRAIN WATER, SEDIMENT FROM FUEL FILTER 1. Open the engine side cover on the left side of the machine, then remove drain plug (1) on the bottom of the fuel filter and drain fuel with sediments and water contained in the fuel. 2.
Page 215: Check Fan Belt Tension, Adjust
V-groove. If any abnormality is found, ask your Komatsu distributor for replacement of the pulley. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.
Page 216: Check, Clean Additioal Fuel Strainer
MAINTENANCE SERVICE PROCEDURE CHECK, CLEAN ADDITIONAL FUEL STRAINER (If equipped) 1. Open the inspection cover at the bottom of the fuel tank. 2. Tighten the fuel supply valve, then remove the cap, and clean the strainer and strainer case. The strainer forms one unit with the cap. 3.
Page 217 6. Clean the removed parts and the inside of the case, then install a new element. Use Komatsu genuine element. 7. Fix cover (6) with bolt (5) by making a horizontal hole of the cover with filter case hole (A).
Page 218: Check Brake Performance
SERVICE PROCEDURE CHECK BRAKE PERFORMANCE WARNING If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately. NOTICE Do not place the gear shift lever in 1st under any circumstances. The machine will be damaged.
Page 219: Clean Air Conditioner Air Filter (Fresh/Recirc Filter)
MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (Machine equipped with cab) Clean the air conditioner air filter if it becomes clogged or if there is dirt or oil stuck to it. In places where there is a lot of dust, clean the air filter once a week. In addition, clean the air conditioner air filter at the same time, when cleaning the engine air cleaner.
Page 220: Every 500 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 500 HOURS SERVICE Maintenance for every 50 and 250 hours service should be carried out at the same time. REPLACE FUEL FILTER CARTRIDGE WARNING The engine is at high temperature immediately after the machine has been operated. Wait for the engine to cool down before replacing the filter.
Page 221 MAINTENANCE SERVICE PROCEDURE METHOD OF USING AUTOMATIC AIR BLEED MECHANISM (if equipped) WARNING The engine will start, so check carefully that the area around the engine is safe before cranking. NOTICE When the engine has run out of fuel, turn the starting switch key to the START position and rotate the starting motor for 15 to 20 seconds to crank the engine and bleed the air.
Page 222: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
2. Loosen drain plug (P) (with a slit) slowly to avoid getting oil on yourself, and drain the oil. 3. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. 4. Install drain plug (P).
Page 223: Every 1000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 50, 250 and 500 hours should be carried out at the same time. CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN 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 224 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 3. Loosen mounting bolt (3) of the power train strainer, then remove cover (4). 4. Take out spring (5), then take out strainer (6). 5. Remove all dirt from strainer (6), then wash in clean diesel oil or flushing oil.
Page 225: Check Oil Level In Damper Case, Add Oil
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 226: Change Oil In Final Drive Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN FINAL DRIVE CASE WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. 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 227 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 2. Remove seal (3) installed to the frame. 3. Remove the breather (4) and wash out dust remaining inside with diesel oil or flushing oil. Power train case breather (1 place) 4. Tighten filter cover (1) and then bolt (2). NOTICE When replacing seal (3), do it after closing cover (1).
Page 228: Grease Universal Joint
MAINTENANCE SERVICE PROCEDURE GREASE UNIVERSAL JOINT WARNING The undercover is heavy. Never try to open or close the cover when directly beneath it. When removing bolts(2), carry out the work from the rear of the cover so that you can easily get out of the way. 1.
Page 229: Replace Corrosion Resistor Cartridge
If a loose bolt is found, tighten it to a torque of 927 ± 103 Nm (94.5 ± 10.5 kgm , 684 ± 76 lbft) If a damaged bolt is found, replace the bolt with a genuine Komatsu bolt. 4 - 66...
Page 230: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 231 7. Remove bolt (8) of filter case (7) and then cover (9). 8. Remove filter (10). 9. Clean the inside of the case and removed parts. Install a new filter. Always use Komatsu genuine filter. 10. Install drain plug (3). 11. After replacing, run the engine and leave the air-bleeding plug (11) loose, then tighten plug (11) when all air is released.
Page 232: Replace Hydraulic Tank Breather Element
MAINTENANCE SERVICE PROCEDURE REPLACE HYDRAULIC TANK BREATHER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it. 1.
Page 233: Change Oil In Damper Case
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. Never try to open or close the cover when directly beneath it.
Page 234: Clean, Check Turbocharger
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced. CHECK ALTERNATOR, STARTING MOTOR The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspection and repairs.
Page 235: Every 4000 Hours Service
CHECK WATER PUMP Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any problem is found, please contact your Komatsu distributor for repairs or replacement. 4 - 72...
Page 236 5 - 1...
Page 237: Specifications
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS POWER TILTDOZER WITH CAB Item Unit D65E-12 D65P-12 Operating weight kg (lb) 18,700 (41,234) 20,100 (44,321) (not including operator) Komatsu 6D125E-2 Komatsu S6D125E-2 Name of engine deisel engine deisel engine Engine horsepower kW (HP)/rpm 132 (177)/1,950 140 (187)/1,950...
Page 238 6 - 1...
Page 239: Attachments, Options
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 240: Handling Hydraulic Ripper
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER HANDLING HYDRAULIC RIPPER This ripper is applicable for the D65E. GENERAL VIEW Hydraulic cylider Shank Link Point Beam Support 6 - 3...
Page 241: Explanation Of Components
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER WARNING When carrying out inspection or maintenance of the machine, or when parking the machine, lower the ripper to the ground and set the work equipment lock lever to the LOCK position. This lever is used to operate the ripper.
Page 242: Operation
ATTACHMENTS, OPTIONS HANDLING HYDRAULIC RIPPER OPERATION CHECK BEFORE STARTING ENGINE, ADJUST WALK-AROUND CHECK 1. Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the rivets. If any 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 243 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). ADJUSTING DIGGING ANGLE Adjust the position of the mounting pin hole in the beam and upper link.
Page 244: Troubleshooting
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 245: Maintenance
Set the blade perpendicular and lower it the ground, lower the ripper to the ground, then stop the engine. 2. For details of checking the oil level in the hydraulic tank, see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL (PAGE 4-48)". SPECIFICATIONS Item Unit D65E-12 Weight of ripper as individual 1,610 part (lb) (3,550)
Page 246: Handling Towing Winch
ATTACHMENTS, OPTIONS HANDLING TOWING WINCH HANDLING TOWING WINCH 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. EXPLANATION OF COMPONENTS Winch control lever Winch lock knob...
Page 247: Operation
ATTACHMENTS, OPTIONS HANDLING TOWING WINCH OPERATION WARNING Injury death could result if the control lever is operated incorrectly during winch operations, so always do as follows. Do not operate in a different way from the method given in this manual. Always wear leather gloves when handling wire rope.
Page 248 ATTACHMENTS, OPTIONS HANDLING TOWING WINCH OPERATION The over-winding method is used with the towing winch: the wire rope is wound in and out from the top of the drum. 1. After starting the engine, set the winch lock knob to the FREE position and release the winch control lever from the LOCK position.
Page 249 ATTACHMENTS, OPTIONS HANDLING TOWING WINCH WINDING OUT 1. When the winch control lever is moved from the NEUTRAL position (N) to Reverse rotation position (2), the brake is released, the drum rotates in reverse, and the wire rope is wound out. 2.
Page 250 ATTACHMENTS, OPTIONS HANDLING TOWING WINCH INCHING (BRAKE PARTIALLY APPLIED) WARNING If the winch lever is pushed in to the end, it is hitched at the brake releasing position (5). Since this is dangerous, do not push in the lever to the end. If it is hitched, return it by hand. This mode is used to move the vehicle forward without changing the position of the load hung on the wire rope.
Page 251: Handling Wire Rope
ADJUSTING ADJUSTING CLUTCH If any abnormality is found, please contact your Komatsu distributor for inspection and repairs. ADJUSTING BRAKE If the wire rope can be wound out from the drum when the winch control lever is at the N position, the brake is not working, so please contact your Komatsu distributor for inspection and repairs.
Page 252: Service Procedure
ATTACHMENTS, OPTIONS HANDLING TOWING WINCH SERVICE PROCEDURE INITIAL 250 HOURS SERVICE Perform the following maintenance only after the first 250 hours. Change gear case oil and clean strainer For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE. EVERY 1000 HOURS SERVICE CHANGE GEAR CASE OIL AND CLEAN STRAINER WARNING...
Page 253: Specifications
5. After adding oil, remove oil level plug (G) and check the oil level. If the oil is not near the bottom edge of the plug hole, add oil through oil filler port (F). SPECIFICATIONS Item Unit D65E-12 D65P-12 Weight of winch kg (lb) 1,290 (2,844) (dry weight) 6,095...
Page 254: Deluxe Seat
ATTACHMENTS, OPTIONS DELUXE SEAT DELUXE SEAT WARNING When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK position to prevent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 255 ATTACHMENTS, OPTIONS DELUXE SEAT (E) Adjusting direction of seat NOTICE Depending on the position of the seat, when changing the direction of the seat, it may contact the console or other parts. Be extremely careful. Pull up lever (5) to unlock the seat. The seat can then be turned 15° to the right. After changing the direction of the seat, return the lever securely to lock the seat.
Page 256: Headrest
ATTACHMENTS, OPTIONS HEADREST HEADREST Removal of headrest Pull up the headrest. REMARK The headrest cannot be fixed to halfway. 6 - 19...
Page 257: Handling Accumulator
Never make any hole in the accumulator or expose it to flame or fire. Do not weld any boss to the accumulator. When disposing the accumulator, it is necessary to release the gas from the accumulator, so please contact your Komatsu distributor.
Page 258: Equipping Fire Extinguisher And First-Aid Kit
The fire extinguisher and the first-aid kit can be installed to the positions shown in the following illustration. (1) First Aid Kit (2) Fire Extinguisher For information on parts which are required to install these items on the machine, call your Komatsu distributor. 6 - 21...
Page 260: Index
INDEX INDEX <A> <H> ADJUSTING POSTURE OF WORK HANDLING ACCUMULATOR 6- 20 EQUIPMENT 3- 90 METHOD OF RELEASING AIR CONDITIONER, HANDLING 3- 34 PRESSURE IN OPERATING CIRCUIT ASHTRAY 3- 33 ON MACHINE EQUIPPED WITH ACCUMULATOR 6- 20 <C> HANDLING HEATER 3- 40 CAP, COVER WITH LOCK 3- 31...
Page 261 AND LUBRICANT 4- 11 WEAR PARTS LIST RECOMMENDED BRANDS, WEAR PARTS LIST 4- 10 RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 13 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 12 <S> SAFETY SAFETY INFORMATION...
Page 263 D65E-12, D65P-12 BULLDOZER Form No. TEN00061-01...

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