Komatsu Utility 69001 Operation & Maintenance Manual Download Page 214 | Manualshive

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SERVICE PROCEDURE

MAINTENANCE

4-36

CHECK LEVEL OF REFRIGERANT

WARNING

If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of
sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.
Do not bring any flame close to any point where the refrigerant gas is leaking.

If the level of the refrigerant (gas) is low, the cooling effect will
be reduced. Run the engine at high idle, and check the flow of
the refrigerant gas (freon 134a) in the refrigerant circuit through
the sight glass (2) (inspection window) of the receiver (1) when
the cooler is running at high speed.

q

(A) Correct: No bubbles are included in the flow

q

(B) Low: Bubbles are included in the flow

(bubbles pass continuously)

q

(C) None: Colorless, transparent

REMARK

When there are bubbles, the refrigerant gas level is low, so
contact your refrigerant dealer to have refrigerant added. If the
air conditioner is run with the refrigerant gas level low, it will
cause damage to the compressor.
New Freon R134a is used as the refrigerant.

OPERATING AIR CONDITIONER OFF-SEASON

Even during the off-season, operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all
parts of the compressor.

GREASE DOOR HINGE

4

(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.

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Summary of Contents for 69001

Page 1: ...y cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine Operation Maintenance Manual EEAM024400 WARNING ...

Page 2: ......

Page 3: ...FOREWORD 11 ...

Page 4: ...nsibility to take the necessary precautions to ensure safety In no event should you or others engage in the prohibited uses or actions described in this manual Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death If you sell the machine be sure to give this manual to the new owner together with the machine Always keep this Operation and Mai...

Page 5: ...estions regarding information contained in this manual q The numbers in circles in the illustrations correspond to the numbers in in the text For example 1 1 Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped If this machine has been purchased in another country it may lack certain safety devices and spec ifications that ...

Page 6: ...onal injury or death Follow the instructions in the safety message The following signal words are used to alert you to information that must be followed to avoid damage to the machine This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided could result ...

Page 7: ... its intended purpose levels of vibration for the earth moving machine transmitted from the opera tor s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096 q If equipped with air suspension seat The actual acceleration value for the hands and arms is less than or equal to 2 5 m s The actual acceleration value for the body is less than ...

Page 8: ...d linkages 3 Keep the terrain where the machine is working and traveling in good condition q Remove any large rocks or obstacles q Fill any ditches and holes q Site manager should provide machine operators with machine and schedule time to maintain terrain con ditions 4 Use a seat that meets ISO 7096 and keep the seat maintained and adjusted q Adjust the seat and suspension for the weight and size...

Page 9: ...nes can be effective to minimize risks of low back pain q Operate the machine only when you are in good health q Provide breaks to reduce long periods of sitting in the same posture q Do not jump down from the cab or machine q Do not repeatedly handle and lift loads ...

Page 10: ...ction WORK POSSIBLE USING BULLDOZER 3 88 for further details GENERAL VIEW AND DIRECTIONS OF MACHINE 1 In this manual the directions of the machine front rear left right are determined according to the view from the operator s seat in the direction of travel front of the machine 1 Blade 7 Sprocket 2 Tilt cylinder 8 Track frame 3 Lift cylinder 9 Step 4 Cab 10 Frame 5 ROPS guard 11 Idler 6 Track shoe...

Page 11: ...ve the ground Shaded area A in the figure shows an area whose view is blocked by part of the machine Operate the machine fully aware that the machine has a portion that an operator cannot see 12M CIRCUMFERENCE VISIBILITY 1 The figure below shows a visibility from the machine within a circle of 12 m in radius Shaded area B in the figure shows an area whose view is blocked by part of the machine Ope...

Page 12: ... hours as indicated on the service meter Make sure that you fully understand the content of this manual and pay careful attention to the following points when breaking in the machine q Run the engine at idle for 15 seconds after starting it During this time do not operate the control levers or fuel control dial q Idle the engine for 5 minutes after starting it up q Avoid operation with heavy loads...

Page 13: ...se inform your Komatsu distributor of the following PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE 1 This is at the front bottom right of the operator s seat The design of the nameplate differs according to the territory ENGINE SERIAL NO PLATE POSITION 1 The engine serial No plate is located on the side of the engine front cover on the left side of the machine ...

Page 14: ...1 12 ADDITIONAL EPA NAMEPLATE 1 The additional EPA nameplate is located on top of the engine head cover on the left side of the machine EPA Environmental Protection Agency U S A SERVICE METER POSITION 1 The service meter is provided at the lower part of the monitor panel ...

Page 15: ...RIBUTOR 1 13 TABLE TO ENTER SERIAL NO AND DISTRIBUTOR 1 Machine serial No Engine serial No Product Identification Number PIN Manufacturers name Address KOMATSU LTD 3 6 Akasaka Minato ku 101 Tokyo Japan Distributor Address Phone Service personnel for your machine ...

Page 16: ...CATION OF PLATES TABLE TO ENTER SERIAL NO AND DISTRIBUTOR FOREWORD 1 14 MACHINE SERIAL NUMBER PLATE 1 Model Seriel Number Manufacturing year Weight Engine power Product Identification Number Manufacturer ...

Page 17: ...PLATES TABLE TO ENTER SERIAL NO AND DISTRIBUTOR 1 11 PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE 1 11 ENGINE SERIAL NO PLATE POSITION 1 11 ADDITIONAL EPA NAMEPLATE 1 12 SERVICE METER POSITION 1 12 TABLE TO ENTER SERIAL NO AND DISTRIBUTOR 1 13 MACHINE SERIAL NUMBER PLATE 1 14 SAFETY IMPORTANT SAFETY INFORMATION 2 2 SAFETY LABELS 2 4 POSITION FOR ATTACHING SAFETY LABELS 2 5 SAFETY LABE...

Page 18: ... COVER 3 46 ASHTRAY 3 46 CUP HOLDER 3 47 TOOL BOX 3 47 SHOVEL HOLDER 3 47 AIR CONDITIONER HANDLING 3 48 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 3 48 METHOD OF OPERATION 3 50 PRECAUTIONS WHEN USING 3 51 SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE 3 51 INSPECTION DURING OFF SEASON 3 51 PROCEDURE FOR REPLACING RECEIVER 3 51 CHECK COMPRESSOR BELT TENSION AND REFRIGERANT ...

Page 19: ...HAT WILL OBSTRUCT THE VIEW 3 87 PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES 3 88 WORK POSSIBLE USING BULLDOZER 3 88 DOZING 3 88 SMOOTHING 3 89 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING 3 89 FELLING TREES REMOVING STUMPS 3 89 ADJUSTING POSTURE OF WORK EQUIPMENT 3 90 ADJUST ANGLE OF BLADE EDGE 3 90 ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT 3 91 ADJUSTING TENSION OF CENTER B...

Page 20: ...DISCHARGED 3 113 REMOVE AND INSTALL BATTERY 3 114 PRECAUTIONS FOR BATTERY CHARGING 3 114 STARTING ENGINE WITH BOOSTER CABLE 3 115 OTHER TROUBLE 3 117 ELECTRICAL SYSTEM 3 117 MONITOR PANEL 3 118 CHASSIS 3 119 ENGINE 3 121 MAINTENANCE GUIDE TO MAINTENANCE 4 2 OUTLINE OF SERVICE 4 5 HANDLING OIL FUEL COOLANT AND PERFORMING OIL CLINIC 4 5 OIL 4 5 FUEL 4 6 COOLANT AND WATER FOR DILUTION 4 6 GREASE 4 7 ...

Page 21: ...D 4 21 CHECK CLEAN AND REPLACE AIR CLEANER ELEMENT 4 21 CLEAN INSIDE OF COOLING SYSTEM 4 24 CHECK TRACK SHOE TENSION ADJUST 4 27 CHECK AND TIGHTEN TRACK SHOE BOLTS 4 29 REVERSE AND REPLACE END BITS AND CUTTING EDGES 4 30 CLEANING AND INSPECTION OF FINS OF RADIATOR OIL COOLER CONDENSER AND AFTER COOLER 4 32 CHECK ADJUST AIR CONDITIONER 4 35 GREASE DOOR HINGE 4 36 CHECK DOOR LOCK STRIKER 4 37 REPLAC...

Page 22: ...4 63 REPLACE CORROSION RESISTOR CARTRIDGE 4 64 CHECK FOR LOOSE ROPS MOUNT BOLTS 4 64 INSPECTION OF AFTER COOLER CIRCUIT FOR LOOSENED BOLTS AND NUTS 4 64 EVERY 2000 HOURS SERVICE 4 65 CHANGE OIL IN HYDRAULIC TANK REPLACE OIL FILTER ELEMENT 4 65 REPLACE HYDRAULIC TANK BREATHER ELEMENT 4 66 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR FOR CONTROL CIRCUIT 4 66 CHANGE OIL IN DAMPER CASE 4 69...

Page 23: ...STARTING ENGINE ADJUST 6 5 PRECAUTIONS WHEN OPERATING 6 5 ADJUSTING POSTURE OF WORK EQUIPMENT 6 5 TROUBLESHOOTING 6 7 OTHER TROUBLE 6 7 MAINTENANCE 6 7 EVERY 250 HOURS SERVICE 6 7 SPECIFICATIONS 6 8 AIR SUSPENSION SEAT 6 9 DELUXE SEAT 6 12 HEADREST 6 14 EQUIPPING FIRE EXTINGUISHER AND FIRST AID KIT 6 15 INDEX COLOPHON ...

Page 24: ...CONTENTS 1 22 ...

Page 25: ...ING Please read and make sure that you fully understand the precautions discribed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precaustions strictly ...

Page 26: ... 2 162 PRECAUTIONS DURING OPERATION 2 172 EXAMINATION AND CONFIRMATION OF WORKSITE 2 172 WORKING ON LOOSE GROUND 2 172 DO NOT GO NEAR HIGH VOLTAGE CABLES 2 172 ENSURE GOOD VISIBILTY 2 182 CONFIRMATION OF MARK 2 182 PRECAUTION FOR WARNING TAG 2 182 CHECK BEFORE STARTING ENGINE ADJUST 2 182 PRECAUTIONS WHEN STARTING 2 192 STARTING WITH BOOSTER CABLES 2 192 CHECK BEFORE STARTING OPERATION 2 202 PRECA...

Page 27: ...RESSURE HOSES PIPING 2 262 PRECAUTIONS WITH HIGH PRESSURE OIL 2 272 PRECAUTIONS WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION 2 272 DO NOT DISASSEMBLE RECOIL SPRING 2 272 ACCUMULATOR 2 282 MAINTENANCE OF AIR CONDITIONER 2 282 WASTE MATERIALS 2 282 PRECAUTIONS FOR MACHINE 2 292 PRECAUTIONS WHEN USING ROPS Roll Over Protective Structure 2 292 ...

Page 28: ...re that they are in the correct place and always keep them clean When cleaning the labels do not use organic solvents or gasoline They may cause the labels to peel off q 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 q There ...

Page 29: ...BELS 2 5 POSITION FOR ATTACHING SAFETY LABELS 2 SAFETY LABELS 2 1 Caution before operating or maintaining machine 09651 A0641 q Warning q Read manual before operation maintaince disassembly assembly and transportation ...

Page 30: ...to lock position and take engine key with you before leaving machine 4 Caution with high temperature coolant hydraulic oil 09653 A0481 q Never remove the cap when the engine is at operating high temperature Stream or high temperature oil blowing up from the radiator or hydraulic tank will cause personal injury and or burns q Never remove the radiator or hydraulic tank oil filler when cooling water...

Page 31: ...ust ment window cover q Sign indicates a hazzard of flying plug from track adjuster that could cause injury q Read the manual and adjusting track for safe and proper handling 7 Caution for battery cable 09808 A0881 q Sign indicates an electric hazzard from handling the cable q Read the operation and maintenance manual and carrying out the correct method when handling 8 Stop rotation during inspect...

Page 32: ...ly injury or fire 11 Caution for ROPS 09620 B2000 ROPS CERTIFICATION This protective structure complies with the standard provided that is properly equipped on the machine which mass is less than the specified maximum mass WARNING q If some modification is applied to the ROPS It might not enough strength and might not be complied with the standard Consult Komatsu Distributor before altering q ROPS...

Page 33: ...ication is applied to the FOBS It might not enough strength and might not be complied with the standard Consult Komatsu Distributor before altering q FOBS may provide less protection if it has been structurally damaged or involved roll over Consult Komatsu Distributor in that case q Always wear seat belt when moving 1 MODEL 2 MACHINE MODEL 3 SERIAL NO 4 FOPS LEVEL No ...

Page 34: ...learances Keep in mind that rain snow ice loose gravel soft ground etc change the oper ating capabilities of your machine Study the Manual before starting the machine If there is something in the Manual you do not understand ask your supervisor to explain it to you PREPARE FOR SAFE OPERATION q Check the Safety Equipment To protect you and others around you your machine may be equipped with the fol...

Page 35: ... immediate action is taken in case of injury the extent of the injury can be reduced Keep the first aid kit in the specified place check the contents periodically and replace any items that have been used or are missing KEEP THE MACHINE CLEAN To avoid the risk of injury q If there is mud or oil stuck to the machine you may slip and fall when getting on or off the machine wipe off any mud or oil st...

Page 36: ...r serious injury when landing q Never get on or off a moving machine You may be unable to support yourself with the handrail or steps and fall from the machine suffering injury Even if the machine starts off with no operator on it do not jump on the machine and try to stop it INSIDE OPERATOR S COMPARTMENT q When entering the operator s compartment always wipe off all mud and oil from the soles of ...

Page 37: ...t procedures are not followed when stopping the machine the machine may suddenly move off with no operator on it This may lead to serious personal injury Always observe the following precautions strictly q Before leaving the operator s compartment lower the work equipment to the ground operate work equipment lock lever 1 and parking brake lever 2 to the LOCK L posi tion and then stop the engine q ...

Page 38: ...iner in a place where there is no danger of the con tents igniting q Use non flammable flushing oil when washing parts Do not use fuel or gasoline or any other fluid that may ignite q Do not weld or use a gas cutter on pipes or tubes con taining flammable fluids q Store fuel and oil in a place where there is good venti lation q Store fuel and oil in the specified place do not store more than the s...

Page 39: ...he battery if the battery electro lyte is below the LOWER LEVEL mark Always carry out periodic inspection of the battery electrolyte level and add distilled water to the UPPER LEVEL mark q Do not smoke or bring any flame close to the battery q Remove the battery from the machine take it to a well ventilated place remove the battery caps then carry out the charging After charging tighten the batter...

Page 40: ... 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 BE CAREFUL ABOUT ASBESTOS DUST If you breathe in air containing asbestos dust there is danger that that...

Page 41: ...y collapse q The ground on embankments or close to ditches may collapse under the weight or vibration of the machine causing the machine to tip over or fall and resulting in injury to the operator Take action to ensure that the ground is safe before starting operations DO NOT GO NEAR HIGH VOLTAGE CABLES Electrocution can result from contacting or approaching underground or overhead power cables Ne...

Page 42: ...machine may tip over or fall resulting in injury to the operator Make sure that all operation personnel understand the meanings of all the signs PRECAUTION FOR WARNING TAG When a warning sign of DON T OPERATE is hung to a con trol lever it means the machine is now under repairs or mainte nance Should you operate the machine ignoring the warning sign someone else may get caught up in a rotating par...

Page 43: ...s bodily injury or fire STARTING WITH BOOSTER CABLES If the method of connecting the booster cables is mistaken the battery may explode and cause serious personal injury so always do as follows q Always wear safety goggles and rubber gloves when start ing the engine with booster cable q When connecting a normal machine to a problem machine with booster cables always use a normal machine with the s...

Page 44: ...case of emergency causing a serious personal injury q Do not allow anyone else to ride the machine with you As there is no passenger seat provided there is danger that he or she may be seriously injured when the machine tips over during the operation q Always wear the seatbelt There is danger that you may be thrown out of the operator s seat and suffer serious injury when the brakes are applied su...

Page 45: ...ght up in the ground causing the machine to tip over PRECAUTIONS FOR ACCUMULATED SNOW AND ICE In a snowy or frozen jobsite there is danger that the machine can skid roll over or fall off during the operation or traveling causing a serious personal injury Therefore adhere to the following instructions without fail q Avoid abrupt operation of the machine during the work q Do not enter areas where th...

Page 46: ...ear leather gloves when handling wire rope q Never tow a machine on a slope q During the towing operation never stand between the tow ing machine and the machine being towed q Move the machine slowly and be sure not to apply any sud den load on the wire rope q If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic system the brake works and the ma...

Page 47: ... alert others the machine is in repair KEEP WORK PLACE FOR MAINTENANCE CLEAN AND TIDY q Always clean up spilled oil or grease scattered tools and broken pieces q Do not use water or steam to clean the sensors connectors or the inside of the operator s compartment REPAIR WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip ment There ...

Page 48: ...y out inspection and maintenance use flat firm ground that is safe for the opera tion with no danger of landslide falling rocks or flooding STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE q Always stop the machine before performing any inspection and maintenance q Lower the work equipment to the ground and stop the engine q Operate work equipment lock lever 1 and parking brake lever 2 t...

Page 49: ...hine or work equipment be sure to support them with blocks sturdy enough to withstand their weight If it is neglected to support them the machine or work equipment may fall off causing a serious personal injury or death q Never use concrete blocks for supports They can collapse under even light loads q Make sure the hoists or jacks you use are in good repair and strong enough to handle the weight ...

Page 50: ...o release the pressure inside the radiator then take off the cap PREVENTION BURNS FROM HOT OIL Immediately after the engine is stopped the oil and parts are at high temperature If you touch the oil or parts immediately after the engine is stopped you will suffer burns q Check that the temperature has gone down to a point where the cap can be touched with your bare hand then loosen the cap slowly a...

Page 51: ... oil and suffer injury to your skin or eyes wash the place with clean water and consult a doctor immediately for medical attention PRECAUTIONS WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION Grease inside the track shoe tension adjuster is highly pressur ized Do not make an error in the track shoe tension adjust ment steps because a serious personal injury can be caused by an error Be sure...

Page 52: ...mmering rolling or similar activity q Ask your Komatsu distributor when sealing gas into the cyl inder or replacing gas from it MAINTENANCE OF AIR CONDITIONER q Never touch the refrigerant q Never loosen any parts of the refrigerant circuit q Do not release any refrigerant to the atmosphere WASTE MATERIALS q Always put oil drained from your machine in containers Never drain oil directly onto the g...

Page 53: ...pporting the machine s weight Thus an operator is protected from an accident If this function is hampered a ROPS cab can no longer protect an operator from injury Therefore adhere to the following instructions q Do not modify the ROPS by welding or drilling q If the ROPS has been deformed by a falling object or an overturn either repair or replace it with a new one For the repairs call your Komats...

Page 54: ...PRECAUTIONS FOR MACHINE SAFETY 2 30 ...

Page 55: ...OPERATION 13 WARNING Please read and make sure that you understand the SAFETY section before reading this section ...

Page 56: ...ERAL VIEW 3 GENERAL VIEW OF MACHINE 3 Machine equipped with ROPS cab Machine equipped with ROPS canopy 1 Blade 7 Sprocket 2 Tilt cylinder 8 Track frame 3 Lift cylinder 9 Frame 4 Cab 10 Idler 5 ROPS guard 11 ROPS canopy 6 Track shoe ...

Page 57: ...lighter 14 Information switch 4 Fuel control dial 15 Buzzer cancel switch 5 Steering forward reverse gear shift lever 16 Brake pedal 6 Auto shift down switch 17 Decelerator pedal 7 Preset mode switch 18 Blade control lever 8 Head lamp switch 19 Horn switch 9 Air conditioner panel or heater panel 20 Ripper control lever if equipped 10 Monitor panel 21 Wiper switch 11 Rear lamp switch 22 Room lamp s...

Page 58: ...er 11 Information switch 3 Fuel control dial 12 Buzzer cancel switch 4 Steering forward reverse gear shift lever 13 Starting switch 5 Auto shift down switch 14 Brake pedal 6 Preset mode switch 15 Decelerator pedal 7 Head lamp switch 16 Blade control lever 8 Monitor panel 17 Horn switch 9 Rear lamp switch 18 Ripper control lever if equipped ...

Page 59: ...auge 12 Maintenance caution lamp 4 Hydraulic oil temperature gauge 13 Engine pre heating pilot lamp 5 Fuel level gauge 14 Engine oil pressure caution lamp 6 Hydraulic oil temperature caution lamp 15 Battery charge circuit caution lamp 7 Power train oil temperature caution lamp 16 Display panel B Multi information 8 Fan operation confirmation lamp 17 Water Separator Lamp 9 Filter oil replacement in...

Page 60: ...ation of devices needed for operating the machine To perform suitable operations correctly and safely it is important to completely understand methods of operating the equipment and the meanings of the displays FRONT PANEL 3 A Emergency caution items D Lamp B Caution items E Switch C Meter group ...

Page 61: ...l display and the lamps all light up for 2 seconds that the alarm buzzer sounds for 2 seconds and that KOMATSU SYSTEM CHECK is dis played for 3 seconds on display panel B multi information 1 3 q After 2 seconds the current status of the machine is displayed on liquid crystal display 2 q After 2 seconds the lamp portion 3 goes out q After 3 seconds the operating mode is displayed on display panel B...

Page 62: ...lamp A flash and the alarm buzzer sounds intermittently Take the necessary action immediately ENGINE OIL PRESSURE CAUTION LAMP This lamp 1 indicates low engine oil pressure If the monitor lamp flashes stop the engine and check it imme diately REMARK The alarm buzzer sounds when the starting switch is turned to ON immediately after the engine oil has been changed It does not indicate a problem 1 En...

Page 63: ...t the low idling speed until the green range of the power train oil temperature gauge lights HYDRAULIC OIL TEMPERATURE CAUTION LAMP Lamp 4 indicates a rise in the hydraulic oil temperature When the monitor lamp flashes stop the machine and run the engine at the low idling speed until oil temperature falls WATER SEPARATOR LAMP This lamp 5 warns of a rise in the water level in the water sep arator W...

Page 64: ...e problem location on the caution lamp will flash BATTERY CHARGE CIRCUIT CAUTION LAMP This lamp 1 indicates a problem in the charging system while the engine is running If the monitor lamp flashes check the V belt tension If any problem is found see OTHER TROUBLE 3 117 REMARK This monitor lamp lights when the starting switch is turned to ON immediately after the engine is started or immediately be...

Page 65: ...position if the filter or oil replacement interval has been reached After replacing the indicated filter or oil displayed on display panel B multi information reset the interval For details see METHOD OF USING OIL AND FILTER MAINTENANCE MODE 3 23 The lamp goes out REMARK At the same time the filter or oil replacement interval lamp also lights up or flashes ...

Page 66: ...prox 3 4 of the full speed and run until the coolant temperature enters green range B If red range C lights up during operation and the engine cool ant temperature caution lamp flashes and the alarm buzzer sounds stop the machine run the engine at low idle and wait for the coolant temperature to return to green range B A White range B Green range C Red range 1 Engine coolant temperature gauge 5 En...

Page 67: ... low idle and wait for the oil temperature to go down to green range B A White range B Green range C Red range HYDRAULIC OIL TEMPERATURE GAUGE Gauge 3 indicates the hydraulic oil temperature If the temperature is normal during operation green range B will light If the red range C lights up during operation move the fuel control lever to lower the engine speed to approx 3 4 of the full speed reduce...

Page 68: ...t 2 2nd 3 3rd Example F1 is displayed for FORWARD 1st q Bar graph C around the outside of the display shows the engine speed If the bar graph reaches red range D during operation take action to reduce the engine speed Always keep the bar graph in the green range DISPLAY PANEL B multi information The top and bottom lines in display panel B multi information display information related to the condit...

Page 69: ...er or engine speed Use the information switch to switch the display between the service meter and engine speed For details of switching the display see INFORMATION SWITCH 3 21 Service meter This displays the total number of hours that the machine has been operated Use the display to determine the intervals for periodic maintenance While the engine is running the service meter advances even if the ...

Page 70: ...oint This lamp 1 flashes when the caution lamp flashes and when an action code is displayed on display panel B multi informa tion When the caution lamp A of an emergency warning item flashes or when the part of an action code is displayed the alarm buzzer sounds continuously at the same time 1 Warning lamp 3 Fan operation confirmation lamp 2 Filter oil replacement interval lamp ...

Page 71: ...L AND FILTER MAINTENANCE MODE 3 23 The lamp goes out or stops flashing FAN OPERATION CONFIRMATION LAMP Orange This lamp 3 lights up or flashes in the following operation and the fan begins to turn q When the engine starting switch is turned to the ON posi tion and the engine is started up with this lamp 3 off the fan turns in the normal direction q After the engine starting switch is turned to the...

Page 72: ...ITCHES 3 Machine equipped with cab Machine equipped with ROPS canopy 1 Starting switch 5 Rear lamp switch 2 Auto shift down switch 6 Fan rotation selector switch 3 Preset mode switch 7 Information switch 4 Head lamp switch 8 Buzzer cancel switch ...

Page 73: ...C START position This is the position to start the engine Hold the key at this position while cranking the engine Release the key immediately after the engine has been started The key will return to ON position B when released AUTO SHIFT DOWN SWITCH This switch 2 is used to actuate the auto shift down function and shift the transmission automatically to a low speed range Q OFF position Stopped l O...

Page 74: ...he Q position Qposition Normal rotation Use this switch normally with the fan operation confirmation lamp in the OFF condition Cooling air is blown out to the front from the radiator mask The fan turns in RPM commensurate with the cooling water temperature thus assuring effective cooling of the engine CLN position Cleaning Use this switch with the fan operation confirmation lamp in the ON conditio...

Page 75: ...ed off immediately in order to protect the hydraulic circuit INFORMATION SWITCH This switch 7 is used to operate display panel B multi infor mation When the switch is released it returns automatically to the cen ter position q When display panel B multi information is in the operation mode turn the switch to or to switch the display to service meter or engine speed q When display panel B multi inf...

Page 76: ...n the oil and filter maintenance mode is dis played EXPLANATION OF MODES AND OPERATION The maintenance mode has the following 4 sub modes Use information switch 1 and buzzer cancel switch 2 to operate each mode Sub mode Function Reference items Oil filter maintenance mode Oil or filter replacement time is dis played METHOD OF USING OIL AND FILTER MAINTENANCE MODE 3 23 PM clinic auxiliary mode The ...

Page 77: ...e replace them immediately If the controllers or monitor panel are replaced the timer for this function will not work properly Contact your Komatsu distributor for replacement Operating mode Hold for 2 5 sec Detailed item display Detailed item display Detailed item display Detailed item display Oil filter maintenance mode PM clinic auxiliary mode Fault code display mode Adjustment mode To oil filt...

Page 78: ...applicable item then operate the buzzer cancel switch to U The screen will ask if you want to display the replacement his tory Operate the information switch to select YES then operate the buzzer cancel switch to U The replacement quantity will increase by 1 the replacement interval will be reset and the oil filter change interval lamp will go out When this is done if the maintenance caution lamp ...

Page 79: ...e table below The items can be selected by operating the information switch REMARK Items such as the engine speed fluctuate and are difficult to see during the measurement In such cases operate the buzzer cancel switch to U This makes it possible to hold the display of the value To cancel this mode operate the buzzer cancel switch again to U To return to the maintenance mode operate the buzzer can...

Page 80: ...determined the condi tion of the machine the display is as shown in the diagram on the right With this function existing failures can be displayed up to a maximum of 20 items If multiple failures are occurring the display automatically changes every 2 seconds so check the code 1 The display is shown repeatedly REMARK To return to the maintenance mode operate the buzzer cancel switch to t METHOD OF...

Page 81: ... or not Entering this mode when the front lamps are lit makes it possible to adjust the brightness when the front lamps are lit In the same way entering this mode when the front lamps are not lit makes it possible to adjust the brightness when the front lamps are not lit 5 Adjusting backlighting of display panel B multi information 6 The diagram on the right is the mode for adjusting the brightnes...

Page 82: ...t the brightness when the front lamps are not lit 9 Adjusting contrast of liquid crystal display panel B multi information 10 The diagram on the right is the mode for adjusting the con trast of the liquid crystal display panel B multi information On this screen operate the buzzer cancel switch to U to switch to the screen to adjust the contrast 11 The contrast can be adjusted by operating the info...

Page 83: ...ENTS 3 29 SWITCHES 3 Machine equipped with cab Machine equipped with ROPS canopy 1 Fuel control dial 5 Cigarette lighter 2 Horn switch 6 Accessory socket 3 Room lamp switch 7 Rear glass heating switch 4 Wiper switch EU specification ...

Page 84: ...he 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 A ON position Lamps light up B OFF position Lamps are out WIPER SWITCH This 4 activates the wipers The wiper switches are as follows A Left door LH B Front window FF C Right door RH D Rear window RR E Wiper intermittent operation switch INT This is also used as t...

Page 85: ...ll be sprayed out q Only wind washer If this is kept to the OFF position K water will be sprayed out q Wiper intermittent operation switch When this switch is turned to the ON position J to start the wiper moving the wiper works once in every four sec onds REMARK When the wiper intermittent operation switch is ON position J if the wiper switch for each window is turned ON position J the wiper will...

Page 86: ...igarette lighter is 24V Do not use it as the power source for 12V equipment If it is used so the equipment may fail The capacity of the cigarette lighter is 120W 24V x 5A ACCESSORY SOCKET This 6 is used as the power source for a wireless or other 12V equipment Accessory socket capacity 60W 12V x 5A REAR GLASS HEATING SWITCH This switch 7 is used to actuate the rear glass heater wire defroster in o...

Page 87: ...osition shown in the diagram q When parking the machine or when carrying out maintenance always lower the work equipment to the ground then set the work equipment lock lever to the LOCK position This lever 1 is a lock device for the work equipment control lever L LOCK position Work equipment does not move even when work equipment control lever is operated F FREE position Work equipment moves accor...

Page 88: ...it switch is actuated and it is impossible to start the engine STEERING FORWARD REVERSE GEAR SHIFT LEVER This control lever 3 serves to change forward or reverse direction of machine travel steer the machine to the right or left change the traveling speed and make a counter rotation q Forward reverse shifting Position A FORWARD Position B REVERSE Position N NEUTRAL Operate the lever to the front t...

Page 89: ...lay panel When the parking brake lever is locked P is displayed For details of the method of shifting gears according to the shift mode see the SHIFTING GEARS 3 79 Shift mode selection means that the selected speed range is displayed at the NEUTRAL position N before starting q Operating counter rotation turn WARNING When operating the counter rotation turn if the load on the left and right is not ...

Page 90: ...cessarily q When passing over the top of a hill or when a load is dumped over a cliff the load is suddenly reduced so there is danger that the travel speed will also increase suddenly To prevent this depress the decelerator pedal to reduce the travel speed This pedal 5 is used when reducing the engine speed or stop ping the machine When switching between forward and reverse or when stop ping the m...

Page 91: ...If the lever is in the FLOAT position even when it is released it does not return to the HOLD position so return it by hand If the engine is stopped when the control lever is in the FLOAT position the lever is returned automatically to the HOLD posi tion In low temperatures it may take a short time for the blade con trol lever to be held in the FLOAT position so hold the lever in position for at l...

Page 92: ...If the lever is in the FLOAT position even when it is released it does not return to the HOLD position so return it by hand If the engine is stopped when the control lever is in the FLOAT position the lever is returned automatically to the HOLD posi tion In low temperatures it may take a short time for the blade con trol lever to be held in the FLOAT position so hold the lever in position for at l...

Page 93: ... tilt operation changes as follows G H J K Rear pitch Front pitch Pitch gauge Standard pitch Pitch condition Tilt operation D65EX D65PX D65WX Amount of tilt Max forward pitch Only left tilt operation is possible Max 870 mm Max 890 mm Max 820 mm Forward pitch H Both left and right tilt operations are possi ble Compared with standard LEFT tilt is LARGER RIGHT tilt is SMALLER Standard pitch K 460 mm ...

Page 94: ...ccording to external force REMARK If the lever is in the FLOAT position even when it is released it does not return to the HOLD position so return it by hand If the engine is stopped when the control lever is in the FLOAT position the lever is returned automatically to the HOLD posi tion In low temperatures it may take a short time for the blade con trol lever to be held in the FLOAT position so h...

Page 95: ...d wiring from damage caused by an abnormal current in the same way as a normal fuse After repairing and restoring the location of the abnormality there is no need to replace the breaker It can be used again 1 Open the cover at the bottom of the front panel Circuit breakers 1 and 2 can be seen Circuit breaker 2 is installed only on machines equipped with an air conditioner 2 When the circuit breake...

Page 96: ...el FUSE CAPACITY AND CIRCUIT NAME Fuse box A Fuse box B NO Fuse capacity Circuit 1 20A Spare power source 2 20A Horn Ribbon heater Air suspension seat 3 20A Front lamp Rear lamp 4 20A Transmission Steering controller 5 5A Engine controller NO Fuse capacity Circuit 1 5A Backup alarm 2 15A Continuous power source 3 30A Truck power source 4 30A Engine power source 5 30A Air conditioner ...

Page 97: ...ttery cover on the left side of the truck you can see fusible link 1 and 2 Capacity of fusible link 1 65A Capacity of fusible link 2 120A ELECTRIC POWER TAKE OUT ADAPTER 3 MACHINE EQUIPPED WITH CAB 3 NOTICE The power for the cigarette lighter is 24V Do not use it as the power source for 12V equipment The cigarette lighter socket 1 can be used as a power source for 24V equipment and the accessory s...

Page 98: ...ff Connector CN800 3 can be used DOOR OPEN LOCK 3 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 To release the door move lever 2 inside the cab to the front of the cab This will release the catch NOTICE q When keeping the door open fix it securely to the catch q Always close the door w...

Page 99: ...is in the FREE position F the glass can be opened or closed q When the lever is in the LOCK position L the glass is held in position DOOR POCKET 3 Machine equipped with cab This is inside the left and right doors Use it for storing the Operation and Maintenance Manual or other things Do not put heavy tools or other heavy objects in it If the pocket is dirty turn 4 clips 1 then remove the pocket an...

Page 100: ...ng the cover always release the gas damper lock first If the gas damper lock is not released and any attempt is made to close the cover the gas damper may break Push the orange button in the center of the gas damper 1 to release the lock then push the cover down ASHTRAY 3 This is on the left side of the operator s seat Always make sure that you extinguish the cigarette before clos ing the lid ...

Page 101: ...the surrounding area or equipment dirty Please make full use of the cup holder TOOL BOX 3 The tool box is inside the battery check cover at the rear left Keep the tools in this box SHOVEL HOLDER 3 If equipped This can be used for storing a shovel with a rounded blade q Method of installing 1 Position the shovel with stopper 1 and holder 2 2 Tighten the adjustment nut 3 so the shovel does not move ...

Page 102: ...ing environment even on dusty jobsites GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 3 FAN SWITCH This switch 1 can be used to adjust the airflow in four stages It also acts as the main switch for the air conditioner When the OFF switch is pressed the fan stops When the switch is pressed the indicator lamp above the switch lights up to display the airflow 1 Fan switch 5 Defroster 2 Air condition...

Page 103: ...r is dirty Intake of fresh air from outside Press this switch C to carry out heating or cooling with fresh air taken in from the outside Use this position when fresh air is taken in from outside the cab or when removing the mist from the cab windows REMARK When fresh air is taken into the cab air pressure in the cab increases which prevents the dust from entering When neither heating nor cooling i...

Page 104: ...ch so that all lamps are red This will improve defrosting and demisting WHEN NOT USING THE AIR CONDITIONER REGULARLY Run the air conditioner in cooling or dehumidification heating mode for several minutes from time to time to pre vent the loss of the oil film in various parts of the compressor REMARK If the temperature inside the cab is low the air conditioner may not work In such cases use the re...

Page 105: ... middle of the dashboard are turned so that cold air blows directly on the cab door glass moisture may condense on the outside of the cab door glass and reduce the visibility This occurs particularly in high temperatures If this happens close the louvers of the vent and change the direction to prevent the cold air from blowing directly on the surface of the glass INSPECTION DURING OFF SEASON 3 Eve...

Page 106: ...iccant If you remove the blind cover connect the piping quickly evacuate the system and fill with refrigerant q When removing the refrigerant from the refrigerant circuit release it gradually from the low pressure side to prevent oil from flowing out CHECK COMPRESSOR BELT TENSION AND REFRIGERANT GAS LEVEL 3 If the compressor belt is loose or the refrigerant level is low cooling is not carried out ...

Page 107: ... starting engine for the day s work 1 Check for damage wear play in work equipment cylinders linkage and hoses Check that there are no cracks excessive wear or play in the work equipment cylinders linkage or hoses If any problem is found repair it 2 Remove dirt and debris from around the engine battery and radiator Check for dirt accumulated around the engine and radiator Also check for flammable ...

Page 108: ...re is any damage replace with new parts CHECK BEFORE STARTING 3 Always check the items in this section before starting the engine each day 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 Open the engine side cover on ...

Page 109: ...the engine has been operated allow the engine to cool for 15 minutes before checking CHECK DUST INDICATOR 1 Open engine side cover on the left side of machine 2 Check if a yellow piston in the display of dust indicator 1 has moved into the red area 7 5 kPa 3 If the yellow piston has already moved into the red area 7 5 kPa either clean the filter element or replace it with new one immediately For c...

Page 110: ...eparator is in one piece with fuel pre filter 1 and located in the lower part 2 Through transparent cap 2 a water level and sediments if any can be seen When water and sediments have accu mulated put a container beneath drain hose 3 3 Loosen plug 4 to drain water and sediments 4 When draining is finished be sure to screw in plug 4 Specified tightening torque 0 2 to 0 45 N m 0 02 to 0 046 kgf m ...

Page 111: ...n then turn the cap slowly to release the pres sure before removing it 1 Open up inspection cover 1 on the right side of the truck to check if a cooling water level in sub tank 2 remains within the FULL LOW range If not refill the tank with clean water up to the FULL level through the filler port in sub tank 2 REMARK In summer the coolant may overflow from the sub tank drain hose This is no proble...

Page 112: ...per ated allow the engine to cool for 15 minutes before checking CHECK ELECTRIC WIRING CAUTION If the circuit breakers are activated and the fuses are blown frequently or there is a trace of short circuit ing in the wirings check the cause immediately and either correct it by yourself or call your Komatsu dis tributor for the repair Keep the top surface of the battery clean and check the breather ...

Page 113: ...t the distance of travel A at the center of the pedal is 70 to 90 mm 3 When this value exceeds 91 mm or the brake fails to work please contact your Komatsu distributor for adjustment CHECKING WITH MACHINE MONITOR 1 Turn starting switch 1 to the ON position B 2 Check that all the monitors and gauges light up for approx 2 seconds and the alarm buzzer sounds for approx 2 sec onds REMARK If the lamps ...

Page 114: ...ch back to the OFF position 2 After completing work fill the fuel tank through fuel filler port F Fuel capacity 415 liters 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 If breather hole 1 on the cap is clogged the pressure in the tank will drop and fuel will not flow Clea...

Page 115: ...not light check for a broken bulb or disconected wire contact your Komatsu distributor for repairs 1 Turn starting switch to the ON position B 2 Turn the Head lamp and Rear lamp switches to the l posi tion ON and check that all the lamps light up 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 distr...

Page 116: ...just to a position where the brake pedal can be fully depressed A Fore and aft adjustment Pull lever 1 set the seat to a position where it is easy to oper ate then release the lever Fore aft adjustment 160 mm 8 stages B Weight adjustment of seat Turn knob 2 under the seat to match the weight adjustment scale with your own weight The weight can be adjusted to 50 to 120 kg REMARK If you want to make...

Page 117: ...5 alternately to adjust the angle of the seat Then release the levers to lock the seat Height adjustment distance 5 stages 60 mm FASTENING AND REMOVING SEAT BELT If equipped WARNING q Before fastening the seat belt check that there is no problem in the securing brackets or belt If there is any wear or damage replace q Even if there appears to be no problem in the seat belt replace the seat belt on...

Page 118: ...d in position 5 When removing the belt press the red button on buckle 3 The belt will automatically retract ADJUST MIRROR If equipped Loosen nut 1 of the mirror and adjust the mirror to a position where it gives the best view from the operator s seat In particular be sure to adjust the mirror so that people at the rear left or right of the machine can be seen clearly ADJUST LEFT CONSOLE BOX WARNIN...

Page 119: ...console box 1 to the desired position until a click is heard Then pull up lock lever 2 and release it Lock lever 2 automatically returns to LOCK position L ADJUST ARMREST The height of the armrest on the left and right sides of the operator s seat can be adjusted to 3 positions After adjusting the operator s seat adjust the armrest to a suitable height ADJUST ARMREST RIGHT Arm rest 1 can be adjust...

Page 120: ...t Turn the knob to adjust as follows Turn CLOCKWISE to move DOWN Turn COUNTERCLOCKWISE to move UP OPERATION AND CHECK BEFORE STARTING ENGINE 3 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 unex...

Page 121: ... 2 is in the NEUTRAL position N REMARK The engine cannot be started if steering forward reverse gear shift lever 2 is not in the NEUTRAL position If steering forward reverse gear shift lever 2 is in FORWARD or REVERSE the letter P on display panel A will flash 3 Check that the blade is lowered to the ground and that blade control lever 3 is in the HOLD position B 4 Check that the work equipment lo...

Page 122: ...under any circum stances If the engine does not start wait for at least 2 minutes then repeat the procedure from Step 2 q Before starting the engine check that the fuel control dial is at the low idle MIN position q The machine is equipped with a function to automati cally warm up engine cooling water temperature more quickly and another function to protect the turbo charger In a cold weather star...

Page 123: ... 69 2 Insert the key into starting switch 2 and turn the key to the START position C The engine will start 3 When the engine starts release the key in starting switch 2 The key will return automatically to the ON position B ...

Page 124: ... ously for more than 60 seconds under any circum stances If the engine does not start wait for at least 2 minutes then repeat the procedure from Step 2 q Before starting the engine check that the fuel control dial is at the low idle MIN position q The machine is equipped with a function to automati cally warm up engine cooling water temperature more quickly and another function to protect the turb...

Page 125: ...changes according to the ambient temperature as shown in the table below 6 When the engine starts release the key in starting switch 2 The key will return automatically to the ON position B REMARK Immediately after an engine startup keep the engine idling and while the engine is idling keep the foot off the deceleration pedal and do not operate the work equipment 7 When the engine rotation stabili...

Page 126: ...en if the fuel control dial is set at above 1000 rpm q While the turbocharger protection function is in operation the engine revolution is held at 1000 rpm even if the fuel control dial is operated q When the turbo protect function is canceled the engine speed is set to the speed for the position of the fuel control dial q The relationship between the length of time of actuating the turbo protect ...

Page 127: ...re than 20 minutes If it is necessary to run the engine at idle apply a load or run at a medium speed from time to time 1 Turn fuel control dial 1 to the mid point between the low idling speed MIN and full speed MAX to start up the engine REMARK The machine holds an engine revolution at 1200 rpm by means of its engine cooling water warming up function until after the engine cooling water temperatu...

Page 128: ...p function until after the engine cooling water temperature reaches 30 C For more details on this function see STARTING IN COLD WEATHER 3 70 2 Blade control lever 2 to the full RAISE position then hold the lever in position and operate slowly to the left tilt relief and right tilt relief positions for 5 minutes 3 Then operate blade control lever 2 to the full RAISE posi tion up to the lever stroke...

Page 129: ...celerate to the maximum speed 6 Check for abnormal exhaust gas color noise or vibration If any problem is found contact your Komatsu dis tributor STOPPING ENGINE 3 NOTICE If the engine is abruptly stopped before it has cooled down engine life may be drastically shortened Do not abruptly stop the engine except for an emergency If the engine has overheated do not stop it abruptly run it at medium sp...

Page 130: ...tion status and then terminate the system While this pro cess continues the main power is maintained The power hold ing time varies depending on the operation condition Also when the cooling fan is used for a cleaning purpose the machine s main power source is not turned off immediately even if engine starting switch 2 key is turned to the OFF posi tion This time lag is provided to protect the hyd...

Page 131: ...ne on a slope always keep brake pedal 7 depressed even after releasing parking break lever 1 q When moving the machine up a steep slope turn fuel control dial 4 to the max position and keep brake pedal 7 and deceleration pedal 5 depressed Then move joystick steering directional and gearshift lever 6 from the N position to the direction of travel and release brake pedal 7 slowly When the travel spe...

Page 132: ...erator pedal 5 5 Operate steering forward reverse shifting gearshift lever 6 to the FORWARD F position or REVERSE R position and gradually release deceleration pedal 5 REMARK Check that the backup alarm buzzer rear side warning buzzer properly sounds when steering forward reverse shifting gearshift lever 6 is operated to the REVERSE R position If it does not call on your Komatsu distribu tor for r...

Page 133: ...e brake disc may make a slipping sound Normally depress decelerator pedal 2 to reduce the engine speed and travel speed before depressing the brake 2 Move steering forward reverse gear shift lever 3 to the NEUTRAL position N depress brake pedal 1 further and stop the machine SHIFTING GEARS 3 The machine does not have to be stopped to shift gears 1 Move steering forward reverse gear shift lever 1 t...

Page 134: ...ed range see SPECIFICATIONS 5 2 REMARK The present speed range is displayed in the center of display panel A 2 1st 1 is displayed 2nd 2 is displayed 3rd 3 is displayed If the machine has failed the speed range and speed range display may change automatically GEARSHIFTING OPERATION USING PRESET MODE FUNCTION 3 If the preset mode function is used the speed ranges used when the machine travels in for...

Page 135: ...tion speed range F2 is automatically selected When steering forward reverse gear shift lever is set to R position speed range R2 is automatically selected REMARK Even when the preset mode function is being actuated it is possible to select the speed range by operating the UP switch or DOWN switch when the machine is traveling forward or in reverse However the preset mode remains set as it is If th...

Page 136: ...he transmission is automatically shifted down F2 F1 F3 F2 R2 R1 R3 R2 REMARK While the preset mode is in operation it is designed the way the machine does not automatically shift up for a safety reason even after it automatically shifts down To shift up press UP U button manually However the preset mode setting remains the same The machine returns to the set travel speed when the steering for ward...

Page 137: ...r life of the power train 1 Depress decelerator pedal 1 to reduce the engine speed 2 Move steering forward reverse gear shift lever 2 to the NEUTRAL position N reduce the speed then depress brake pedal 3 and stop the machine 3 After depressing decelerator pedal 1 move steering for ward reverse gear shift lever 2 to the desired position Position F Forward Position N Neutral Position R Reverse REMAR...

Page 138: ...rward reverse control lever is shifted when the machine is traveling downhill a directional change may automatically take place via 1st gear for safety For example when the forward reverse control lever is shifted from F2 to R2 the directional change may take place in the sequence of F2 to R1 to R2 ...

Page 139: ...ING FORWARD NOTICE If the lever is moved partially to the forward or reverse position and then is moved in the direction of turn the machine may carry out a counterrotation turn so operate the lever fully to the forward or reverse position If steering forward reverse gear shift lever 1 is moved to the FORWARD position F and moved partially to the left L the machine will start to turn gradually Aft...

Page 140: ...me way PRECAUTIONS FOR OPERATION 3 PAY ATTENTION TO GAUGES 3 When the red range lights on the power train oil temperature gauge while operating reduce the load and wait for the temperature to decrease PERMISSIBLE WATER DEPTH 3 When operating in water always keep the bottom of carrier roll ers 1 above the surface of the water Also be careful that the engine cooling fan will not come in contact with...

Page 141: ...n operating machine on sloped areas of more than 20 fill all appropriate components with oil to H level PRECAUTIONS WHEN ENGINE STOPS ON SLOPES If the engine stops while working or traveling on a hill immediately depress the brake pedal to bring the machine to a complete stop METHOD OF USING BRAKES 3 The following actions cause premature damage to the brakes so avoid such operations q Using emerge...

Page 142: ...bstacle or worker in the surrounding area WORK POSSIBLE USING BULLDOZER 3 In addition to the following it is possible to further increase the range of applications by using various attachments DOZING 3 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 When dozing toward one side only operate w...

Page 143: ...make sure that it stays in position To prevent damage to the blade be careful not to travel over any stones or rocks CUTTING INTO HARD OR FROZEN GROUND OR DITCHING 3 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 3 NOTICE Do not uproot trees or stumps or fell trees by angling...

Page 144: ...ting edge angle A increases To decrease the angle shorten the distance Standard blade cutting edge angle A is 55 Standard distance between the joints B is as shown below D65EX 1150 mm D65PX 1146 mm D65WX 1150 mm REMARK When the machine is installed with a fixed type tilt brace a blade cutting edge angle cannot be adjusted Standard blade cutting edge angle A is 55 When the blade cutting edge is hel...

Page 145: ...r damage of the bushing Make this adjustment as follows WARNING Except when operating the blade in Step 4 always lock the blade control lever securely with the work equipment lock lever 1 Adjust with shim 2 so that the play of ball joint 1 is 0 2 to 0 5 mm 2 Loosen bolt 3 3 Install the blade assembly 4 Operate the blade control lever to float the blade 5 Insert bar 4 in the center brace hole and t...

Page 146: ...CE An amount of tilt A can be increased to a maximum of 400 mm Adjust an amount of tilt A within 400 mm 1 Raise the blade up to the height of 400 mm to 500 mm above the ground and put block B beneath the blade edge 2 Loosen the bolt 1 of the brace insert a suitable bar into hole 2 of the brace and turn it REMARK When turning the brace with bar keep the blade above the ground Right tilt Make right ...

Page 147: ...e work equipment securely with the work equipment lock lever q Be careful when removing arm 2 After arm 2 is removed the blade can move freely 1 Raise the blade up to the height of 400 mm to 500 mm above the ground and put block B beneath the blade edge 2 Remove pins 1 on the left and right sides then remove arm 2 from the frame 3 Insert arm 2 into any desired bracket C on the frame three brackets...

Page 148: ... the blade into the ground q If the work equipment control lever is touched by acci dent the work equipment may move suddenly and this may lead to a serious accident Before leaving the operator s seat always operate the work equipment lock lever and parking brake lever to place it securely at the LOCK position 1 Stop the machine For details see STOPPING MACHINE 3 79 2 Set parking brake lever 1 to ...

Page 149: ...pressure fuel level and Power train oil temperature AFTER STOPPING ENGINE 3 1 Walk around the machine and check the work equipment machine exterior and undercarriage also check for any leakage of oil or coolant If any problems are found repair them 2 Fill the fuel tank 3 Check the engine compartment for paper and debris Clean out any paper and debris to avoid a fire hazard 4 Remove any mud affixed...

Page 150: ... Please consult your Komatsu distributor when selecting track shoes q Do not allow shoe slipping to occur during operation If shoe slipping occurs reduce load on the blade until slipping stops q Avoid sudden starts acceleration or stops unnecessary high speeds and sharp turns q Always operate machine in a straight line whenever possible When making turns be careful not to allow the machine to stay...

Page 151: ...use the sprocket teeth to wear prematurely For an inspection and maintenance method see CHECK TRACK SHOE TENSION ADJUST 4 27 Referring to that section carry out an inspection and adjustment of track shoe tension q Check idler rollers for oil leakage as well as for loose bolts and nuts If any trouble is detected repair immediately q Check a clearance B between front idler guide plate 1 and track fr...

Page 152: ... q Link pitch limit for turning 206 mm There is no link window on the master link REMARK The measured value under decimal of link pitch is different from the basic value depending upon the precision of measure or the tolerance of product even if it isn t worn out Don t judge it s worn out too soon do it with the trend of mea sured value after that MEASURING HEIGHT OF GROUSER D65EX D65WX After taki...

Page 153: ...ht 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 3 Calculate outside diameter of tread size A A B C x 2 q Standard size A 210 mm q Repair limits 172 mm ...

Page 154: ...here is danger that the seal may be damaged when remov ing or installing the cab so please contact your Komatsu distributor When installing the cab please contact your Komatsu distributor too PRECAUTIONS WHEN REMOVING WORK EQUIPMENT 3 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 r...

Page 155: ...hine model is D65EX with a 3 m long semi U blade it is not necessary to remove the work equipment because the blade width is less than 3 0 m 4 Tie the tilt hose with a band to prevent it from being dam aged PRECAUTIONS WHEN REMOVING ROPS 3 When removing ROPS for transporting the machine do as follows NOTICE ROPS is an important safety component Be sure to tighten mounting bolts 1 securely to the s...

Page 156: ...on the ramps can cause the machine to tip over If it is necessary to change the travel direction return to the ground or to the bed of the trailer then change the travel direction q The center of gravity of the machine shifts suddenly at the border between the ramps and trailer and the machine is unbalanced and becomes dangerous Accordingly pass the border slowly When loading or unloading always u...

Page 157: ...ly pass the border slowly 8 Stop the machine at the specified position on the trailer 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 Set the work equipment lock lever to the LOCK position L securely...

Page 158: ... 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 If ramps 2 bend appreciably under the weight of the machine put wooden block 5 under the ramps to support th...

Page 159: ...he machine being lifted q Always use a wire rope that has ample strength for the weight of the machine being lifted q Keep the machine horizontal when lifting it q When carrying out lifting operations set the work equipment lock lever and parking brake lever to the LOCK position to prevent the machine or work equipment from moving unexpectedly q Never enter the area under or around a raised machin...

Page 160: ...t and left sides q Fit the wire ropes at the rear to both left and the right pivot shafts 2 For machine equipped with ripper q Fit the wire ropes at the center to both left and the right pivot shafts 2 q Hang the rear wire rope to ripper beam 3 When lifting the machine stop it on a level place then observe the following procedure ...

Page 161: ...ll not be broken at sharp edges or narrow places q Use spreaders and bars having sufficient width so that they will not touch the machine 4 After setting the wire ropes lift up the machine and stop at 100 to 200 mm above the ground and check that the wire ropes are not slack and the machine is level then lift up slowly TRAVELING ON ROADS 3 q When traveling on paved roads use flat shoes to protect ...

Page 162: ...eeze is flammable Do not bring any flame close Do not smoke when handling antifreeze NOTICE q Use Komatsu Supercoolant wherever available or use permanent type antifreeze coolant q Never use methanol ethanol or propanol based antifreeze q Do not use any water leakage prevention agent either alone or in combination with antifreeze q Do not mix one brand of antifreeze with a different brand For deta...

Page 163: ... freezing and making it impossible for the machine to move on the following morning observe the following precautions q Remove all the mud and water from the machine body In particular wipe the hydraulic cylinder rods clean to prevent damage to the seal caused by mud dirt or drops of water on the rod from getting inside the seal q Park the machine on hard dry ground If this is impossible park the ...

Page 164: ...o perform the rust prevention operation while the machine is indoors open the doors and windows to improve ventilation and prevent gas poisoning q During storage operate and move the machine for a short distance once a month so that a new film of oil will coat moving parts At the same time also charge the battery q When operating the work equipment wipe off all the grease from the hydraulic cylind...

Page 165: ...starting switch and turn the key to ON position B Then the electric priming pump begins to work 2 After holding the key in ON position B for 30 seconds turn it back to OFF position A and hold it there for 10 sec onds 3 Repeat Steps 1 and 2 four times 4 Turn the engine starting switch key to START position C to start up the engine 5 If the engine does not start up even after the engine starting mot...

Page 166: ...y any sudden load to the wire rope NOTICE The maximum towing capacity for this machine is 197 100 N 20 100 kgf Always carry out towing operations within the maximum towing capacity For details of the method of towing please contact your Komatsu distributor q If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic system the brake works and the mach...

Page 167: ...rks q Battery electrolyte is dilute sulfuric acid and it will attack your clothes and skin If it gets on your clothes or on your skin immediately wash it off with a large amount of water If it gets in your eyes wash it out with fresh water and consult a doctor q When handling batteries always wear safety glasses and rubber gloves q When removing the battery first disconnect the cable from the grou...

Page 168: ...arger to match the voltage of the battery to be charged If the correct voltage is not selected the charger may overheat and cause an explosion q Connect the positive charger clip of the charger to the positive terminal of the battery then connect the nega tive charger clip of the charger to the negative termi nal of the battery Be sure to attach the clips securely q Set the charging current to 1 1...

Page 169: ... connection is to the engine block of the problem machine but sparks will be gen erated when this is done so connect to a place as far as possible from the battery q When disconnecting the booster cable take care not to bring the clips in contact with each other or with the machine body NOTICE q The starting system for this machine uses 24V For the normal machine also use a 24V battery q The size ...

Page 170: ...rdless of whether the machine is working normally or has failed Check also that all the control levers are in the HOLD or NEU TRAL position 1 Make sure the clips are firmly connected to the battery terminals 2 Start engine of the normal machine and run it at high idle speed 3 Turn the starting switch of the problem machine to the START position and start the engine If the engine doesn t start at f...

Page 171: ...ective alternator Replace Starting motor does not turn when starting switch is turned to ON Defective wiring Insufficient battery charge Check repair Charge Pinion of starting motor keeps going in and out Insufficient battery charge Charge Starting motor turns engine slug gishly Insufficient battery charge Defective starting motor Charge Replace Starting motor disengages before engine starts Defec...

Page 172: ...r Remedy E01 Top line Displays E01 Bottom line Displays service meter Failure in part of function stops When con tinuing operations be extremely careful of location of failure After completing opera tions contact Komatsu distributor for repairs E02 Top line Displays E02 Bottom line Displays service meter Flashes Sounds Serious failure in part of function stops When continuing operations be extreme...

Page 173: ...gauge Defective contact in wiring connec tion Replace oil temperature gauge Check repair Lacks drawbar pull machine does not pick up speed Lack of engine horsepower Oil pressure in torque converter is too low See ENGINE related parts Go to Oil pressure in torque con verter fails to rise Machine will not move when joystick is placed in FORWARD Insufficient oil in power train case Transmission oil p...

Page 174: ...does not rise at all or blade tilts too slowly Lack of hydraulic oil Defective hydraulic pump Work equipment lock lever is in LOCK position Add oil to specified level For details see EVERY 250 HOURS SERVICE Check Set to FREE position Problem Main causes Remedy ...

Page 175: ...rature monitor remains alight altitude operation Engine does not start when starting motor is turned Lack of fuel Air in fuel system No fuel in fuel filter Starting motor cranks engine slug gishly Defective electric priming pump Defective valve compression Add fuel see CHECK BEFORE STARTING Repair place where air is sucked in Replace pump or nozzle See ELECTRICAL SYSTEM See ELECTRICAL SYSTEM Adjus...

Page 176: ...HOOTING OPERATION 3 122 Monitor displays error code Please contact your Komatsu distributor Alarm buzzer sounds Engine horsepower lowered sud denly Engine is running in duration mode Problem Main causes Remedy ...

Page 177: ...OPERATION TROUBLESHOOTING 3 123 ...

Page 178: ...TROUBLESHOOTING OPERATION 3 124 ...

Page 179: ...MAINTENANCE 14 WARNING Please read and make sure that you understand the SAFETY section before reading this section ...

Page 180: ...icles or foreign materials are found always report to the person in charge and carry out suitable action FUEL STRAINER If your machine is equipped with a fuel strainer do not remove it while fueling WELDING INSTRUCTIONS q Turn off the engine starting switch q Do not apply more than 200 V continuously q Connect grounding cable within 1 m of the area to be welded If grounding cable is connected near...

Page 181: ...s locked open before letting go q When standing on the track to open the engine side cover bend at the knees and open the cover in a standing posi tion to avoid back strain q Before opening the cab door always close the engine side cover If the lock for the engine side cover is not released it will not close If any attempt is made to close it without releas ing the lock the gas damper may break Wh...

Page 182: ...e stopped q Have any inspection and maintenance points been forgotten q Have all inspection and maintenance items been performed correctly q Have any tools or parts been dropped inside the machine It is particularly dangerous if parts are dropped inside the machine and get caught in the lever linkage mechanism q Are there any leakage of coolant or oil Have all nuts and bolts been tightened q Check...

Page 183: ...ater metal particles dirt etc from getting in The majority of problems with the machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil q Never mix oils of different grades or brands q Always add the specified amount of oil Having too much oil or too little oil are both causes of problems q If the oil in the work equipment...

Page 184: ...e coolant 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 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 Komatsu ...

Page 185: ...sible to prevent machine failures and downtime With KOWA the oil is periodically sampled and analyzed This enables early detection of wear of the machine drive parts and other problems We strongly recommend you to use this service The oil analysis is carried out at actual cost so the cost is low and the results of the analysis are reported together with recommendations which will reduce repair cos...

Page 186: ...the Operation and Maintenance Manual However when working in severe conditions replace the filters at shorter intervals according to the oil and fuel sulfur content being used q Never try to clean the filters cartridge type and use them again Always replace with new filters q When replacing oil filters check if any metal particles are attached to the old filter If any metal particles are found con...

Page 187: ...or the oil temperature to go down before starting maintenance Even after the temperature has gone down some parts may still be under internal pressure so when loos ening plugs bolts or hose connections do not stand directly in front of the parts and loosen slowly to release the internal pressure before removing q When carrying out inspection and maintenance of the hydraulic circuit always release ...

Page 188: ... ball 1 Fuel main filter 6754 71 6130 Cartridge with cap 1 Every 1000 hours service Corrosion resistor 600 411 1191 Cartridge 1 Hydraulic oil filter 14X 60 31150 07000 15195 Element O ring 1 1 Every 2000 hours service Hydraulic tank breather element 20Y 60 21470 Element 1 Air cleaner 600 185 5100 Element Ass y 1 Air conditioner Fresh filter 14X 911 7750 Filter 2 Recirc filter 20Y 979 6261 Filter 2...

Page 189: ...1 22272 175 71 22282 02090 11495 02290 11422 Cutting edge right Cutting edge left Bolt Nut End bit left End bit right Bolt Nut 37 5 34 0 39 0 39 0 1 1 17 17 1 1 14 14 D65EX Semi U blade 3m tilt dozer 14X 952 1270 02090 11270 02290 11219 150 70 21356 150 70 21346 02090 11280 02290 11219 Cutting edge Bolt Nut End bit left End bit right Bolt Nut 29 8 26 2 26 2 2 14 14 1 1 12 12 D65WX Semi U blade til...

Page 190: ...he daytime tem perature rises to 10 C Always use multigrade oil such as the recommended EO10W30DH or EO15W40DH q If the machine is operated at a temperature below 20 C a separate device is needed so consult your Komatsu distributor q When the fuel sulfur content is less than 0 5 change the engine oil according to the period inspection table given in this Operation and Maintenance Manual q If the f...

Page 191: ...EO10W30DH 15 C 50 C SAE15W40DH Komatsu EO15W40DH 0 C 40 C SAE30DH Komatsu EO30DH Damper case Idler each Power train oil Note 2 30 C 50 C Komatsu TO30 Power train case each Power train oil 30 C 10 C Komatsu TO10 0 C 50 C Komatsu TO30 Final drive case each Power train oil 30 C 40 C Komatsu TO30 Hydraulic system Power train oil 20 C 40 C Komatsu TO10 Hydraulic oil 20 C 45 C Komatsu HO46 HM Engine oil...

Page 192: ...r to prevent squeaking of pins and bushings the use of G2 T or G2 TE is recommended Note 4 Supercoolant AF NAC 1 Coolant has the important function of anticorrosion as well as antifreeze 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 an...

Page 193: ...OMMENDED BRANDS RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4 When using commercially available oils other than Komatsu genuine oil or when checking the latest specifica tions refer to the Komatsu web page or consult your Komatsu distributor ...

Page 194: ...dth across flats b mm Tightening torque Target value Service limit N m kgf m N m kgf m 6 8 10 12 14 10 13 17 19 22 13 2 31 66 113 172 1 35 3 2 6 7 11 5 17 5 11 8 14 7 27 34 59 74 98 123 153 190 1 2 1 5 2 8 3 5 6 0 7 5 10 0 12 5 15 5 19 5 16 18 20 22 24 24 27 30 32 36 260 360 510 688 883 26 5 37 52 3 70 3 90 235 285 320 400 455 565 610 765 785 980 23 5 29 5 33 0 41 0 46 5 58 0 62 5 78 0 80 0 100 0 ...

Page 195: ...ame time as the hoses 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 4 NO Safety critical parts for periodic replacemen...

Page 196: ...tor 1 32 Hose hydraulic oil cooler hydraulic tank 1 33 Hose central drain block HSS motor 1 34 Hose PPC valve main valve 4 35 Hose central PPC block main valve 2 36 Hose fan pump central PPC block 1 37 Hose PPC lock valve central PPC block 1 38 Hose self reducing pressure valve central PPC block 1 39 Hose PPC valve PPC lock valve 1 40 Hose PPC valve central drain block 1 41 Hose central drain bloc...

Page 197: ...4 414 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM 4 424 CHECK BEFORE STARTING 4 EVERY 50 HOURS SERVICE 4 DRAIN WATER SEDIMENT FROM FUEL TANK 4 434 EVERY 250 HOURS SERVICE 4 LUBRICATING 4 444 GREASE EQUALIZER BAR SIDE PIN 4 454 GREASE EQUALIZER BAR CENTER PIN 4 464 CHECK OIL LEVEL IN FINAL DRIVE CASE ADD OIL 4 464 CHECK OIL LEVEL IN HYDRAULIC TANK ADD OIL 4 474 CHECK LEVEL OF BATTERY ELECTROLYTE...

Page 198: ...TANK BREATHER ELEMENT 4 664 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR FOR CONTROL CIRCUIT 4 664 CHANGE OIL IN DAMPER CASE 4 694 CHECK VIBRATION DAMPER 4 704 CHECK ENGINE VALVE CLEARANCE ADJUST 4 704 EVERY 4000 HOURS SERVICE 4 REPLACE ACCUMULATOR FOR CONTROL CIRCUIT 4 714 CHECK WATER PUMP 4 714 CHECKING FOR LOOSENESS OF HIGH PRESSURE CLAMP HARDENING OF RUBBER 4 724 CHECKING FOR MISSIN...

Page 199: ...indicator 1 becomes red 7 5 kPa clean the outer element NOTICE Do not clean the filter element until after a yellow piston in the dust indicator display has come in the red area 7 5 kPa If the filter element is cleaned frequently before the yellow piston in the dust indicator display comes in the red area 7 5 kPa the air cleaner cannot exert its inherent cleaning capability reducing its cleaning e...

Page 200: ...eaned 6 times if the yellow piston in the dust indicator goes to the 5 kPa position immediately after cleaning when the engine is running at high idling replace both the inner and the outer element 8 If small holes or thinner parts are found on the element when it is checked by shining a light through it after clean ing replace the element NOTICE When cleaning the element do not hit or beat it aga...

Page 201: ...ent 5 at this time however 4 Clean the interior of the air cleaner body cover 3 and evacuator valve 6 NOTICE If the outer element and cover are installed when the inner element is not installed properly the outer element may break When installation is correct protrusion a of the inner element from the air cleaner body is 35 mm 5 Remove inner element 5 then quickly install the new inner element Pus...

Page 202: ...p from the operator s seat or leaving the machine set the work equipment lock lever and parking brake lever to the LOCK positions q For the starting method of the engine see CHECK BEFORE STARTING ENGINE ADJUST 3 53 and STARTING ENGINE 3 68 in the OPERATION section of the manual q Never go under the machine body while the engine is running It is very dangerous since the machine may move suddenly Cl...

Page 203: ...mbient temperature but it should always be a minimum of 30 by volume anti freeze total amount of coolant x 100 The freezing temperature of undiluted antifreeze is 15 C Do not store undiluted antifreeze at a temperature of below 15 C Mixing rate of water and antifreeze WARNING Antifreeze is flammable so keep it away from flame Antifreeze is toxic When removing the drain plug be careful not to get w...

Page 204: ...w idling speed After the water temperature rises above 90 C run the engine for about 10 minutes 6 Stop the engine and open drain valve 2 3 to drain the water 7 After draining the water clean the cooling system with cleaning agent For the cleaning method see the instructions for the cleaning agent 8 Replace the corrosion resistor then open 2 valves For details of the procedure for replacing the cor...

Page 205: ...operating on jobsites where the track becomes clogged with mud measure with the track clogged with mud INSPECTION Stop the machine on level ground stop with the transmission in FORWARD without applying the brake Then place a straight bar on the track shoes between the carrier roller and the idler as shown in the figure and measure the clearance between the bar and the grouser at the midpoint If th...

Page 206: ...ed or replaced Please contact your Komatsu distributor WHEN LOOSENING TENSION WARNING It is extremely dangerous to release the grease by any method except the procedure given below If the track tension is not relieved by this procedure please contact your Komatsu distributor 1 Loosen plug 1 gradually to release the grease 2 When loosening plug 1 turn it a maximum of one turn 3 If the grease does n...

Page 207: ... m Then ensure the nut and shoes are in close contact with the link contact surface 2 After checking tighten a further 120 10 METHOD OF TIGHTENING MASTER CONNECTING BOLT 1 First tighten to a tightening torque of 343 39 N m 35 4 kgf m then check that the link contact surfaces are in close contact 2 After checking the link contact surfaces tighten the bolt by 180 Allowable range 0 20 ORDER FOR TIGHT...

Page 208: ...ing 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 Remove the cutting edge and the end bit and clean the mounting surface Item Judgement criteria mm No Dimension to be measured Work equipment Basic dimension Allowable max value 1 Height of end bit outside A G 242 187 B ...

Page 209: ...ess the blade against the ground to elimi nate the play of bolt 2 then tighten the bolt to the speci fied torque Nut tightening torque Powertilt dozer 461 69 N m 47 7 kgf m Powertilt Power pitch dozer 461 69 N m 47 7 kgf m Angledozer 441 49 N m 45 5 kgf m Semi U dozer Cutting edge 461 69 N m 47 7 kgf m End bit 745 108 N m 76 11 kgf m If bolt 2 and nut 1 are damaged replace them with new ones at th...

Page 210: ...ing the cooling fan in the reverse direction 1 Turn starting switch 1 to the OFF position and stop the engine 2 Turn starting switch 1 to the ON position 3 Set fan rotation selector switch 2 to the cleaning position CLN Cooling fan operation checking lamp 3 lights up REMARK Even if it is attempted to reverse a rotation direction of the cool ing fan while the engine is running the rotation directio...

Page 211: ...e and check that the fan is not rotating If you touch the fan when it is rotating it will cause serious personal injury CLEANING OF RADIATOR FINS AND AFTER COOLER FINS When the radiator fins and after cooler fins are clogged or lots of dust is accumulated clean them with com pressed air 1 Remove bolts 1 4 bolts 2 Open the A side hinge side of the radiator mask It opens approx 10 mm 3 Open the B si...

Page 212: ...side covers 1 2 Remove right and left bolts 3 4 bolts in total to remove right and left lower side covers 5 3 Remove right and left bolts 4 8 bolts in total to remove right and left small side covers 6 4 Remove bolts 2 2 bolts in total to remove sub tank assembly together with stay 7 5 Put the removed sub tank assembly on radiator guard seat 8 and temporarily fasten it to radiator guard seat 9 wit...

Page 213: ...and install bolts 11 9 Reassemble the temporarily fastened sub tank assembly in the original position 10 Install right and left lower side covers 5 and small side covers 6 and close the engine side covers CHECK ADJUST AIR CONDITIONER 4 Machine equipped with cab CHECKING TENSION OF COMPRESSOR BELT If the driving belt slackens it is likely to slip lowering the cool ing efficiency Depress the mid poi...

Page 214: ...ing at high speed q A Correct No bubbles are included in the flow q B Low Bubbles are included in the flow bubbles pass continuously q C None Colorless transparent REMARK When there are bubbles the refrigerant gas level is low so contact your refrigerant dealer to have refrigerant added If the air conditioner is run with the refrigerant gas level low it will cause damage to the compressor New Freo...

Page 215: ...ve of door damper rubber 1 is less than 2 mm replace the damper There are 4 dampers 1 each at the top and bottom on the left and right doors CHECK DOOR LATCH 4 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 ...

Page 216: ...d be careful not to let any dust get in PROPORTION FOR MIXING FLUID WITH WATER The proportion differs according to the ambient temperature so dilute the washer fluid with water to the following proportions before adding There are two types depending on the freezing temperature 10 C general use and 30 C cold area use select according to the area and season Area season Proportions Freezing temperatu...

Page 217: ...ipe the window clean so replace the blade REPLACEMENT FRONT DOOR WIPER 1 It is hooked at portion A so move the blade in the direc tion of the arrow to remove it 2 Install the new blade and hook it securely REAR WIPER 1 Remove E ring 1 The blade can then be removed 2 Install a new blade then install securely with E ring 1 ...

Page 218: ...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 REMARK When installing guide plate 2 install the same number and thickness of shim 3 as removed in Step 1 The optimum clearance may be obtained if the adjustment is made at the same time For details of adjusting ...

Page 219: ...AL JOINT 4 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 Remove the undercover from the rear bottom of the machine body as follows 2 Remove two bolts 1 from the front side of the machine body 3 Holding the cover remove two bolts 2 from the ...

Page 220: ...ding air in the tilt hydraulic circuit by repeating left and right tilt operation five to ten times 5 Bleeding air from the bottom of left cylinder by operating the blade to pitch forward and backward 5 to 10 times repeatedly 6 Set the left and right cylinders at the neutral position then carry out the following operations 5 to 10 times to bleed the air from the head end of the left pitch cylinder...

Page 221: ... travel q Checking with machine monitor q Check fuel level add fuel q Check horn sound q Check that lamps light up q Check of operation of backup alarm EVERY 50 HOURS SERVICE 4 DRAIN WATER SEDIMENT FROM FUEL TANK 4 Carry out this check before operating the machine q Prepare a container to catch the fuel that is drained 1 Open cover 1 2 Open valve 2 at the bottom of the tank and drain the sed iment...

Page 222: ...e fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out POWER TILTDOZER 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 Tilt brace ball joint 1 place 6 Brace ball joint 2 places 7 Tilt brace thread 1 place screw adjustable POWER TILT POWER PITCH DOZER 1 Lift cylinde...

Page 223: ... places 5 Tilt brace thread 2 places GREASE EQUALIZER BAR SIDE PIN 4 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 sup ply 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 discharged ...

Page 224: ...n operated Wait for the oil to cool down before starting the operation q If there is still pressure remaining inside the case the oil or plug may fly out Loosen the plug slowly to release the pressure 1 Stop the machine so that drain plug 3 is directly at the bottom 2 Remove oil level plug 2 and check whether the final drive case is filled with oil to lower edge of the plug hole 3 If the oil level...

Page 225: ... release the internal pressure then remove it NOTICE q Do not add oil if the level is above the H line This will damage the hydraulic equipment and cause the oil to spurt out q Always lock the cap with the key 1 Lower blade to the ground and stop the engine Wait for 5 minutes before checking oil level Oil level should be between the H and L in sight gauge G 2 If the level is below the L mark add o...

Page 226: ...rting operations in the morning to prevent the electrolyte from freezing Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is possible to check the electrolyte level from the side of the battery check as follows 1 Open the battery cover on the left side of the machine body 2 Use ...

Page 227: ...bottom of sleeve so poles appear straight and not bent 3 After adding distilled water tighten cap 1 securely REMARK If distilled water is added to above the bottom of the sleeve use a syringe to lower the level to the bottom of the sleeve Neutralize the removed fluid with baking soda sodium bicar bonate then flush it away with a large amount of water or con sult your Komatsu distributor or battery...

Page 228: ... 1 Start the engine 2 Set work equipment lock lever 1 to the FREE position F then operate blade control lever 2 to raise the blade Leave the work equipment lock lever 1 to the FREE posi tion F 3 Set parking brake lever 3 to the FREE position F 4 Depress brake pedal 4 set steering forward reverse gear shift lever 5 in FORWARD then press the shift up button to enter 2nd speed 5 Operate fuel control ...

Page 229: ...and remove it 2 Remove inside cover 3 then remove FRESH filter 4 3 Remove the filter box then brush out the dirt accumulated inside the box through the cleaning hole 5 in the hood When doing this be careful not to let any dirt or dust get into the fresh air intake port 6 leading to the cab 4 Open inspection cover 7 under the front panel then pull up RECIRC filter 8 and remove it 5 Clean filters 4 ...

Page 230: ...pacity 28 liters q Prepare a socket wrench and filter wrench 1 Remove the cover 1 on the bottom of the machine and set a container to catch the drained oil directly under the drain plug 2 Take the end of hose 2 out of the inspection window 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 par ti...

Page 231: ...l or coat thinly with grease then install 11 When installing the filter cartridge bring the packing sur face into contact with the filter holder then tighten a further 3 4 to 1 turn 12 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 13 Run the engine at idle for a short time then stop the engine and check that the...

Page 232: ...e at high temperature so do not replace the filter imme diately Wait for all parts to cool down before starting the operation q High pressure is generated inside the engine fuel piping system when the engine is running When replacing the filter wait for at least 30 seconds after stopping the engine to let the internal pres sure go down before replacing the filter q Do not bring any fire or flame c...

Page 233: ...er cartridge without t fuel When installing the cartridge turn it by 3 4 of a turn after the packing comes to contact with the filter base sealing face If the cartridge is tightened too tightly the packing can be damaged causing fuel to leak On the other hand if it is tightened loosely fuel can also leak through a clearance between the packing and the base Therefore be sure to follow the specified...

Page 234: ... key to ON position B Then the electric priming pump begins to work 16 After holding the key in ON position B for 30 seconds turn it back to OFF position A and hold it there for 10 sec onds 17 Repeat the operation in Step 15 and 16 four times 18 Turn the engine starting switch key to START position C to start up the engine check the filter sealing face and water separator installing face for fuel ...

Page 235: ...e go down before replacing the filter q Do not bring any fire or flame close NOTICE q Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability When replacing the filter cartridge always use a genuine Komatsu part q The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle ...

Page 236: ... the filter holder coat the packing surface of the new filter cartridge thinly with oil then install the filter cartridge to the filter holder 8 When installing tighten until the packing surface contacts the seal surface of the filter holder then tighten it 3 4 of a turn If the filter cartridge is tightened too far the packing will be damaged and this will lead to leakage of fuel If the filter car...

Page 237: ...10 sec onds 13 Repeat the operation in Step 12 and 13 four times 14 Turn the engine starting switch key to START position C to start up the engine and check the filter sealing face for fuel leak If leak is noticed check the filter cartridge for its tightening condition If it is correctly tightened and fuel still leaks remove the filter cartridge once and check the con tact face with the packing fo...

Page 238: ... When remov ing bolts 3 carry out the work from the rear of the cover so that you can easily get out of the way q Refill capacity 48 liters 1 Remove cover 1 at the bottom rear of the machine 2 Loosen drain plug P with slit and drain the oil After draining the oil tighten drain plug P 3 Remove the undercover from the rear bottom of the machine body as follows 4 Remove two bolts 2 from the front sid...

Page 239: ... all dirt from strainer 11 then wash in clean diesel oil or flushing oil Clean the case interior and the removed parts If the spring or strainer are damaged replace them 13 Install the strainers in their original position 14 After installing replace the element in the power train oil filter For details see REPLACE POWER TRAIN OIL FILTER ELEMENT 4 54 15 Open cover on the right side of the machine 1...

Page 240: ...ocedure 1 Remove the undercover from the rear bottom of the machine body as follows 2 Remove two bolts 1 from the front side of the machine body 3 Holding the cover remove two bolts 2 from the rear side of the machine body 4 Lower and open the cover gradually A Front of machine B Dangerous place 5 Remove oil level plug 3 and check the oil level The proper oil level is the bottom edge of the plug h...

Page 241: ...65PX WX each 27 liters 1 Stop the machine so that drain plug 3 is directly at the bottom 2 Remove oil level plug 2 and oil filler plug 1 then remove drain plugs 3 and 4 and drain the oil 3 After draining the oil install drain plugs 3 and 4 4 Add oil to the specified level through the hole in oil filler plug 1 5 Check that the oil is at the specified level For details see CHECK OIL LEVEL IN FINAL D...

Page 242: ...ing screw in cartridge until seal comes in con tact with sealing surface then tighten approx 2 3 turn 5 Open valves 1 2 places CHECK FOR LOOSE ROPS MOUNT BOLTS 4 Check that the bolts are not loose and that there is no damage If any bolt is loose tighten it to the following torque If there is any damage replace the bolt with a genuine Komatsu part Tightening torque 785 to 980 N m 80 to 100 kgf m IN...

Page 243: ...equipment to the ground then stop the engine 2 Turn the cap of oil filler F slowly to release the internal pressure then remove the cap 3 Remove the cover 1 at the bottom of the hydraulic tank 4 Loosen drain valve 2 drain the oil tighten drain valve 2 again then install cover 1 When loosening drain valve 2 be careful not to get oil on yourself 5 Remove bolt 3 then remove cover 4 6 Take out spring ...

Page 244: ...ator is charged with high pressure nitrogen gas so mistaken operation may cause an explo sion which will lead to serious injury or damage When handling the accumulator always do as follows The pressure in the hydraulic circuit cannot be completely removed When removing the hydraulic equip ment do not stand in the direction that the oil spurts out when carrying out the operation In addition loosen ...

Page 245: ...alled to the position shown in the dia gram on the right CHECKING FUNCTION OF ACCUMULATOR 4 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 Raise the work equipment blade to the maximum height NOTICE Carry out the followin...

Page 246: ...hine is safe then operate the blade control lever to the LOWER position 8 Check that the work equipment goes down to the ground under its own weight 9 This completes the inspection NOTICE 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 machi...

Page 247: ... cuit operate the ripper control lever to the right and left to each stroke end 5 Set the work equipment lock lever to the LOCK position CHANGE OIL IN DAMPER CASE 4 WARNING q The parts and oil is very hot just after the operation Wait until the oil temperature drops then start the work q The undercover is heavy Never try to open or close the cover when directly beneath it When removing bolts 2 car...

Page 248: ... reaches the bottom edge of the hole of oil level plug 3 7 After refilling the oil tighten plugs 3 and 4 CHECK VIBRATION DAMPER 4 Check that there are no cracks or peeling in the outside surface of the rubber If any cracks or peeling are found contact your Komatsu distributor to have the parts replaced CHECK ENGINE VALVE CLEARANCE ADJUST 4 Special tools are needed for inspection and maintenance pl...

Page 249: ...s out when carrying out the operation In addition loosen the bolts slowly when carrying out the operation Do not disassemble the accumulator Do not bring it near flame or dispose of it in fire Do not make holes in it or weld it Do not hit it roll it or subject it to any impact When disposing of the accumulator the gas must be released Please contact your Komatsu distributor to have this work carri...

Page 250: ...s hardened If any such abnormality is found call on your Komatsu distributor for repairs or 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 Always check that the proper high pressure piping clamps are correctly instal...

Page 251: ...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 Fuel spray prevention caps 1 through 14 are a protective part that serves to prevent leaked fuel from splashing over highly heated portions of the engine causing fire as a result ...

Page 252: ...2000 and 4000 hours service should be carried out at the same time REPLACE HIGH PRESSURE PIPING CLAMP 4 Contact your Komatsu distributor to have the engine high pressure clamps replaced REPLACE FUEL SPLAY PREVENTION CAPS 4 Contact your Komatsu distributor to have the fuel spray prevention cap replaced ...

Page 253: ...SPECIFICATIONS 15 ...

Page 254: ...nditioner Item Unit D65EX 15 D65PX 15 D65WX 15 Machine weight kg 20 280 21 000 21 140 Name of engine Komatsu SAA6D114E 3 diesel engine Engine horsepower ISO9249 kw HP rpm 153 205 1 950 A Overall length mm 5 440 5 520 5 440 B Overall height mm 3 220 3 220 3 220 C Overall width mm 3 460 3 970 3 640 Travel speed 1st 2nd 3rd Forward km h 3 3 6 3 10 1 Reverse km h 4 4 8 2 12 9 ...

Page 255: ...ATTACHMENTS OPTIONS 16 WARNING Please read and make sure that you understand the safety section before reading this section ...

Page 256: ...removal and installation When removing or installing an attachment observe the following items and work safely Select a firm level surface when installing or removing an attachment When working in cooperation with one or more other workers decide signs and observe them when carry ing out the operation When carrying a heavy part 25 kg or more use a crane When removing a heavy part always place a su...

Page 257: ...TACHMENTS OPTIONS HANDLING HYDRAULIC RIPPER 6 3 HANDLING HYDRAULIC RIPPER 6 q This hydraulic ripper is for D65EX and D65WX dozers GENERAL VIEW 6 1 Hydraulic cylider 4 Shank 2 Link 5 Point 3 Beam 6 Support ...

Page 258: ... the ground and set the work equipment lock lever to the LOCK position This lever is used to operate the ripper A RAISE Ripper goes up B HOLD Ripper is stopped and held in the same position C LOWER Ripper goes down REMARK If the work equipment lock lever is set to LOCK position L the operation of the ripper is locked For details of the operation of the work equipment lock lever see WORK EQUIPMENT ...

Page 259: ...n the machine suddenly or travel in reverse When turning the machine suddenly or traveling in reverse raise the shank from the ground surface q When carrying out digging operations with only one shank always use the center shank Remove both side shanks q When starting to travel up a steep slope or when reaching the bottom of the slope the point may touch the ground On hard ground there is danger o...

Page 260: ...Adjust the position of the mounting pin hole in the beam and upper link q Digging angle Position 1 45 Position 2 55 The pin is locked with lock plate 3 REPLACEMENT OF POINT A point is installed to protect the shank If the point is worn replace it as follows 1 Put a pin remover in contact with the pin marked by the arrow and tap with a hammer to remove 2 Replace the point 3 Insert the pin half way ...

Page 261: ...in causes Remedy Slow ripper raising and function lack of ripping force Improper hydraulic oil Defective pump Defective adjustment of relief valve Defective control valve safety valve Defective valve spool Defective piston ring packing valve Clogging inside piping Add oil to specified level see EVERY 250 HOURS SERVICE Check repair Check repair Check repair Check repair Check repair Cylinder lacks ...

Page 262: ...he 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 4 47 SPECIFICATIONS 6 D65EX Power tilt dozer with ROPS guard cab and air conditioner D65WX Semi U dozer with ROPS guard cab and air conditioner Item Unit D65EX 15 D65WX 15 Operating weight not including operator kg 21 400 22 820 Weight of ripper a...

Page 263: ...n release the lever Fore aft adjustment 170 mm 17 stages B Adjusting seat angle Move lever 2 up move the seat cushion at the front up or down to set to the desired position then release the lever Amount of adjustment Forward tilt 3 degrees Rear tilt 11 degrees C Setting seat for operator s weight To protect the operator it is necessary to adjust the suspension to match the weight of the operator P...

Page 264: ...ement of the lever To prevent the suspension from reaching the bottom do not set to the seat height below the adjustment range E Fore and aft adjustment of seat cushion Operate lever 4 up set the seat cushion to the desired position then release the lever Fore and aft adjustment 60 mm F Adjusting reclining angle Move lever 5 up and move the backrest to the front or rear Push your back against the ...

Page 265: ...e headrest up or down and set to the desired height Amount of adjustment 100 mm I Lumbar support Operate switch 6 to give a suitable tension to the lumbar region When is pressed Tension becomes stronger When is pressed Tension becomes weaker Adjust the backrest to the desired curve ...

Page 266: ...ever Fore aft adjustment 200 mm 10 stages B Weight and height adjustment of seat q Turn knob 2 under the seat so that weight adjustment indicator 3 displays the green range The height can be adjusted by turning the knob 2 while the green range is displayed q Turn the knob clockwise to raise the seat and turn the knob counterclockwise to lower the seat Height adjustment range stepless 75 mm Weight ...

Page 267: ...rection 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 q Change the direction of the seat to the right for the ease of operation of the ripper ...

Page 268: ...HEADREST ATTACHMENTS OPTIONS 6 14 HEADREST 6 Removal of headrest Pull up the headrest REMARK The headrest cannot be fixed to halfway ...

Page 269: ...uisher and the first aid kit at the illustrated position needs brackets if equipped The fire extinguisher and the first aid kit can be installed to the positions shown in the following illustration 1 First Aid Kit 2 Fire Extinguisher For information on parts which are required to install these items on the machine call your Komatsu distributor ...

Page 270: ...EQUIPPING FIRE EXTINGUISHER AND FIRST AID KIT ATTACHMENTS OPTIONS 6 16 ...

Page 271: ...INDEX 17 ...

Page 272: ...INDEX 7 2 ...

Page 273: ... 2 GENERAL VIEW OF CO 3 3 GENERAL VIEW OF MACHINE 3 2 GUIDE TO MAINTENANCE 4 2 H HANDLING HYDRAULIC RIPPER 6 3 EXPLANATION OF COMPONENTS 6 4 GENERAL VIEW 6 3 MAINTENANCE 6 7 OPERATION 6 5 SPECIFICATIONS 6 8 TROUBLESHOOTING 6 7 HANDLING HYDRAULIC SYSTEM 4 9 HANDLING OIL FUEL COOLANT AND PERFORMING OIL CLINIC 4 5 HEADREST 6 14 I IMPORTANT SAFETY INFORMATION 1 4 2 2 INTENDED USE 1 8 BREAKING IN THE N...

Page 274: ... POSITION FOR ATTACHING SAFETY LABELS2 5 SAFETY LABELS 2 5 SASH GLASS INTERMEDIATE LOCK 3 45 SERVICE PROCEDURE 4 21 CHECK BEFORE STARTING 4 43 EVERY 1000 HOURS SERVICE 4 57 EVERY 2000 HOURS SERVICE 4 65 EVERY 250 HOURS SERVICE 4 44 EVERY 4000 HOURS SERVICE 4 71 EVERY 50 HOURS SERVICE 4 43 EVERY 500 HOURS SERVICE 4 52 EVERY 8000 HOURS SERVICE 4 74 WHEN REQUIRED 4 21 SHIFTING GEARS 3 79 SHOVEL HOLDE...

Page 275: ...COLOPHON 18 ...

Page 276: ...COLOPHON 8 2 D65EX 15 D65PX 15 D65WX 15 GALEO BULLDOZER Form No EEAM024400 2006 KOMATSU All Rights Reserved Printed in Belgium 01 06 ...

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