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Komatsu D61EX-24 Operation & Maintenance Manual Download Page 326

MAINTENANCE SCHEDULE

If the currently used diesel fuel which does not include the bio-fuel is changed to the one mixed with the bio-fuel,
the replacement interval of the fuel filter is changed as well. See “MAINTENANCE INTERVAL WHEN DIESEL
FUEL MIXED WITH BIO-FUEL IS USED”.

MAINTENANCE SCHEDULE TABLE

WHEN REQUIRED ........................................................................................................................................ 4-15

METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER.......................................... 4-15
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM ................................................................. 4-20
METHOD FOR CLEANING INSIDE MACHINE....................................................................................... 4-23
METHOD FOR CHECKING AND CLEANING RADIATOR FRONT......................................................... 4-23
METHOD FOR CHECKING AND ADJUSTING TRACK TENSION ......................................................... 4-24
METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE BOLTS .......................... 4-26
METHOD FOR CHECKING IDLER OIL LEVEL ...................................................................................... 4-27
METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE..................................................... 4-27
METHOD FOR INVERTING AND REPLACING CUTTING EDGE AND END BIT ................................... 4-28
CLEAN AND CHECK RADIATOR FINS AND OIL COOLER FINS .......................................................... 4-29
METHOD FOR CLEANING HYDRAULIC TANK BREATHER ................................................................. 4-33
METHOD FOR CLEANING FUEL TANK BREATHER............................................................................. 4-33
METHOD FOR REPLACING DOOR DAMPER....................................................................................... 4-34
METHOD FOR LUBRICATING DOOR HINGE........................................................................................ 4-34
METHOD FOR CHECKING DOOR LATCH ............................................................................................ 4-34
METHOD FOR CHECKING DOOR LOCK STRIKER.............................................................................. 4-35
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID ................................. 4-35
METHOD FOR CHECKING WIPER BLADE ........................................................................................... 4-36
METHOD FOR REPLACING WIPER BLADE ......................................................................................... 4-36
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER................................................. 4-38
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT .............................................................. 4-39
METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT ..................................................... 4-40
METHOD FOR CHECKING ELECTRICAL INTAKE AIR HEATER .......................................................... 4-40
METHOD FOR ADJUSTING SHIMS AT CENTER BALL ........................................................................ 4-41

CHECKS BEFORE STARTING...................................................................................................................... 4-42
EVERY 50 HOURS MAINTENANCE ............................................................................................................. 4-43

METHOD FOR LUBRICATING ............................................................................................................... 4-43
METHOD FOR LUBRICATING EQUALIZER BAR CENTER PIN............................................................ 4-44

EVERY 250 HOURS MAINTENANCE ........................................................................................................... 4-45

METHOD FOR LUBRICATING ............................................................................................................... 4-45
METHOD FOR LUBRICATING EQUALIZER BAR SIDE PIN .................................................................. 4-45
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL ..................................... 4-46
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL ............................................................. 4-46
METHOD FOR CHECKING BRAKE PERFORMANCE........................................................................... 4-49

EVERY 500 HOURS MAINTENANCE ........................................................................................................... 4-50

METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE .....

............................................................................................................................................................ 4-50

METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................... 4-52
METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC FILTERS ....................................... 4-55

EVERY 1000 HOURS MAINTENANCE ......................................................................................................... 4-57

METHOD FOR CHANGING OIL IN FINAL DRIVE CASE ....................................................................... 4-57
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE ............................................................ 4-58
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT......................................................... 4-60
METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS.............. 4-60
METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ............................................. 4-61
METHOD FOR REPLACING DEF TANK BREATHER ELEMENT........................................................... 4-62
CHECK AND REPLACE ALTERNATOR DRIVE BELT TENSION AND REPLACING ALTERNATOR BELT....

............................................................................................................................................................ 4-64

METHOD FOR CHECKING FOR LOOSE ROPS MOUNT BOLTS ......................................................... 4-64

EVERY 2000 HOURS MAINTENANCE ......................................................................................................... 4-65

MAINTENANCE

MAINTENANCE SCHEDULE

4-13

Summary of Contents for D61EX-24

Page 1: ...s necessary contact your local distributor for availability NOTICE Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it WARNING ...

Page 2: ...lifornia to cause cancer birth defects and other reproductive harm CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer birth defects and reproductive harm Wash hands after handling FOREWORD 1 1 ...

Page 3: ...tenance Manual Storing Place It is provided on the back side of the operator s seat back If this manual is lost or damaged contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No immediately to arrange for its replacement For details regarding the machine model name and the serial No see the machine serial No plate In order to arrange the proper Ope...

Page 4: ... safety mes sage 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 in death or serious injury This signal word indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used...

Page 5: ...ees and removing stumps For details of work procedure see OPERATION RECOMMENDED APPLICATIONS DIRECTIONS OF MACHINE In this Operation and Maintenance Manual the directions of the machine front rear right left are determined according to the view from operator s seat E in the direction of travel front of the machine A Front B Rear C Left D Right E Operator s seat F Sprocket INTRODUCTION FOREWORD 1 4...

Page 6: ...ft 3 in away from the outside surface of the machine 12 m radius visibility The figure below shows a visibility from the machine for a radius of 12 m 39 ft 4 in Shaded area B in the figure shows an area whose view is blocked by a part of the machine when the machine is equipped with the mirrors and other visibility assistant devices Be fully aware that there is an area where the operator cannot se...

Page 7: ...nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel Exhaust Fluid DEF Diesel Exhaust Fluid is the aqueous urea solution for the SCR system DEF is the abbreviation for Diesel Exhaust Fluid and is represented as DEF throughout this manual DEF is a colorless transparent and aqueous urea solution made with 32 5 urea AUS32...

Page 8: ... items LOCATION OF PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE It is located at front left of the operator s seat The design of the nameplate varies according to the district LOCATION OF ENGINE NUMBER PLATE It is located under the air cleaner at the right side of the machine FOREWORD PRODUCT INFORMATION 1 7 ...

Page 9: ... displayed on the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Distributor name Address Phone Fax Service personnel PRODUCT INFORMATION FOREWORD 1 8 ...

Page 10: ...S RELATED TO ATTACHMENTS AND OPTIONS 2 15 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2 15 PRECAUTIONS FOR OPERATION 2 16 PRECAUTIONS FOR JOBSITE 2 16 START ENGINE 2 19 PRECAUTIONS FOR OPERATION 2 21 PRECAUTIONS FOR TRANSPORTATION 2 25 TOWING AND BEING TOWED 2 26 PRECAUTIONS FOR MAINTENANCE 2 27 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2 27 PRECAUTIONS FOR CHECK AND MAINTENANCE 2...

Page 11: ...IO 3 233 EXPLANATION OF RADIO EQUIPMENT 3 233 METHOD FOR CONTROLLING RADIO 3 236 ANTENNA 3 238 TRANSPORTATION 3 239 TRAVEL ON ROAD 3 239 PRECAUTIONS FOR TRANSPORTING MACHINE 3 239 TRANSPORTATION PROCEDURE 3 239 REMOVE CAB 3 239 METHOD FOR REMOVING WORK EQUIPMENT 3 239 LOADING AND UNLOADING WITH TRAILER 3 240 METHOD FOR LIFTING MACHINE 3 243 COLD WEATHER OPERATION 3 245 COLD WEATHER OPERATION INFOR...

Page 12: ...OURS MAINTENANCE 4 45 EVERY 500 HOURS MAINTENANCE 4 50 EVERY 1000 HOURS MAINTENANCE 4 57 EVERY 2000 HOURS MAINTENANCE 4 65 EVERY 4000 HOURS MAINTENANCE 4 78 EVERY 4500 HOURS MAINTENANCE 4 82 EVERY 8000 HOURS MAINTENANCE 4 83 EVERY 9000 HOURS MAINTENANCE 4 84 SPECIFICATIONS 5 1 SPECIFICATIONS 5 2 SPECIFICATIONS D61EX 24 5 2 SPECIFICATIONS D61PX 24 5 3 ATTACHMENTS AND OPTIONS 6 1 GENERAL PRECAUTIONS...

Page 13: ...L COOLANT AND LUBRICANT 7 5 LUBRICATION CHART 7 6 METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA TURE 7 8 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7 9 INDEX 8 1 TABLE OF CONTENTS FOREWORD 1 12 ...

Page 14: ...ase read and make sure that you fully understand the precautions descri bed in this manual and the safety labels on the machine When operating or servicing the machine always follow these precautions strictly 2 1 ...

Page 15: ...rly When cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the safety labels see this manual or the actual label and place an order to your Komatsu distributor There are also other labels in addition to the warning s...

Page 16: ...Caution for handling accumulator 7 Caution for adjusting track tension 8 Caution for handling cable 9 Stop rotation during inspection and maintenance 10 Caution for approaching while moving machine 11 Prohibition of start by short circuiting 12 Caution for handling battery 13 Caution for handling ROPS FOPS 14 Caution for blast site 15 Caution when traveling in reverse 16 Caution for handling DEF S...

Page 17: ...CONTENTS OF SAFETY LABELS Caution for operation inspection and maintenance 09651 03001 Caution for safety at rear 09802 13000 SAFETY LABELS SAFETY 2 4 ...

Page 18: ...on when leaving operator s seat 09654 33001 Caution for high temperature coolant 09668 03001 Caution for high temperature oil 09653 03001 Caution for handling accumulator 09659 53000 SAFETY SAFETY LABELS 2 5 ...

Page 19: ...ndow Caution for handling cable 09808 03001 Stop rotation during inspection and maintenance 09667 43000 Improper use of jumper cables and battery cables can cause an explosion resulting in serious injuly or death Follow instructions in manual when using jumper cable and battery cables WARNING 09808 03001 SAFETY LABELS SAFETY 2 6 ...

Page 20: ...h Voltage Open flames or sparks could cause battery to explode May form explosive air gas mixture during charging Store and use in well ventilated area Extremely flammable gas hydrogen Explosion Fire Blast or Projectile hazard Do not handle or charge until all safely precautions instructions have been read and understood Wear protective gloves protective clothing eye protection and face protection...

Page 21: ...Caution for blast site 09845 13000 only machine with KOMTRAX Caution when traveling in reverse 09833 33000 only machine with camera Caution for handling DEF 09632 31800 SAFETY LABELS SAFETY 2 8 ...

Page 22: ...n this manual that you do not understand ask the person in charge of safety for explanation PREPARATIONS FOR SAFE OPERATION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method of the safety related devices and use them properly Never remove any safety related...

Page 23: ...ot leave tools or machine parts lying around inside the operator s compartment If tools or parts get into the control devices it may obstruct operation and cause the machine to move unexpectedly resulting in serious personal injury or death Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire Do not use a cellular phone when driving or operating the machine T...

Page 24: ...d surfaces or on parts of the electrical system After adding fuel or oil wipe up any spilled fuel or oil Put greasy rags and other combustible materials into a safe container to maintain safety at the workplace When washing parts with oil use a non flammable oil Do not use diesel fuel or gasoline There is danger that they may catch fire Do not weld or use a cutting torch to cut any pipes or tubes ...

Page 25: ...s This machine is equipped with Komatsu Diesel Particulate Filter hereafter KDPF KDPF is a device to purify the soot in the exhaust gas Exhaust gas temperature may increase during the purifi cation process regeneration Do not bring any combustible material close to the outlet of the exhaust pipe When there are thatched houses dry leaves or pieces of paper near the job site set the system to the re...

Page 26: ...ff immediately not to slip if any In addition tighten any loose bolt of the handrails and steps If the handrails and steps are damaged or deformed they need to be repaired immediately Ask your Komatsu dis tributor to perform this work Do not grip the control levers parking brake lever or work equipment lock lever when getting on or off the machine Never climb on the engine hood or covers where the...

Page 27: ...h Always observe the following When leaving the machine always lower the work equipment completely to the ground set work equipment lock lever 1 and parking brake lever 2 to LOCK position L and stop the engine In addition lock all places and always take the key with you and keep it in the specified location EMERGENCY EXIT FROM OPERATOR S CAB The machine equipped with the cab has the doors on its r...

Page 28: ... not fasten your seatbelt properly it cannot display its effect Always fasten your seat belt while operating the machine UNAUTHORIZED MODIFICATION Komatsu will not be responsible for any personal injuries product failures physical loss or damage or influ ence on the environment resulting from modifications made without authorization from Komatsu Any modification made without authorization from Kom...

Page 29: ...machine during operation In particular if you need to operate on a road protect pe destrian and cars by designating a person for jobsite traffic duty or by installing fences around the jobsite When traveling or operating in shallow water or on soft ground check the water depth speed of the current con dition of bedrock and shape of the ground beforehand Always avoid any place that will obstruct tr...

Page 30: ...e machine during operation If the machine should come too close or touch the electric cable to prevent electric shock the operator should not leave the operator s compartment until it has been confirmed that the electricity has been shut off Also prohibit any other persons to come close to the machine ENSURE GOOD VISIBILITY Although this machine is equipped with mirrors and cameras to ensure good ...

Page 31: ...ust in the air can cause lung cancer if it is inhaled There is danger of inhaling asbestos when working on jobsite where demolition work is performed or industrial waste is han dled Always observe the following Spray water to keep down the dust Do not use compressed air If there is danger that there may be asbestos dust in the air always operate the machine from an upwind position and make sure th...

Page 32: ...window glass to ensure a good view Perform the walk around check Remove all dirt from the surface of the lens of the headlamps and working lamps and check that they light up correctly Check the coolant level fuel level DEF level and oil level in engine oil pan check for clogging of the air cleaner and check for damage to the electric wiring Check that there is no mud or dust accumulated around the...

Page 33: ...lectrolyte before starting START ENGINE WITH JUMPER CABLES If any mistake is made in the method of connecting the jumper cables it may cause the battery to explode so always observe the following Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cables When connecting a normal machine to a failed machine with the jumper cables always use the normal ma...

Page 34: ...l the doors and windows of the operator s compartment in position regardless of whether it is open or closed Always close all the windows and doors on jobsites where there is danger of scattering fragments and things which may intrude into operator s cab Prohibit other personnel to get on the machine If there are any persons in the area around the machine there is danger that they may be hit or ca...

Page 35: ... has to travel over an obstacle keep the work equipment close to the ground and travel at low speed The machine tips over easily to the right or left Do not drive it over obstacles which make the machine tilt largely to the right or left When driving the machine on the rough ground drive it at low speed and do not operate the steering suddenly There is a danger that the machine may tip over The wo...

Page 36: ...that the machine may slip Drive the machine at low speed on the grass or fallen leaves Even with slight slopes there is a hazard that the machine may slip Depress the brake pedal or use the engine brake as necessary PRECAUTIONS WHEN OPERATING MACHINE Be careful not to approach too close to the edge of cliffs When making embankments or landfills or when dropping soil over a cliff dump one pile then...

Page 37: ...e engine brake while applying the foot brake intermittently depress the brake intermittently several times If necessary lower the work equipment to the ground to stop the machine PRECAUTIONS WHEN PARKING MACHINE Unexpected move of the parked machine can cause serious personal injury or death Always observe the fol lowing Park the machine on a firm level ground Select a place where there is no haza...

Page 38: ...ing slope Take suitable steps to prevent the ramps from moving out of position or coming off 1 Chocks 2 Ramp 3 Center of ramp 4 Angle of ramp Max 15 Be sure the ramp surface and the platform of trailer are clean and free of grease oil ice water and other loose materials If any remove them Remove dirt around the undercarriage of the machine On a rainy day in particular be extremely careful since th...

Page 39: ...ys confirm that the wire rope or drawbar used for towing has ample strength for the weight of the ma chine being towed Never use the wire rope which has cut strands A re duced diameter B or kinks C There is a danger that the rope may break during the towing operation Always wear leather gloves when handling the wire rope Never tow a machine on a slope During the towing operation never stand betwee...

Page 40: ...her tools lying around in the work place Wipe up all grease oil or other substances that will cause you to slip Always keep the work place clean the tidy to enable you to perform operations safely If the work place is not kept clean and tidy there is the danger that you will trip slip or fall over and injure your self SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE Stop the machine on a firm ...

Page 41: ...ch to ON position set work equip ment lock lever 2 to FREE position F operate the blade control lever and the ripper control lever to RAISE and LOWER position 2 to 3 times repeatedly to release the re maining pressure in the hydraulic circuit then set parking brake lever 1 and work equipment lock lever 2 to LOCK position L Check that the battery relay is off and main power is not conducted After t...

Page 42: ...undings of KDPF become high temperature When performing the maintenance work stop the regener ation of KDPF Set work equipment lock lever 1 and parking brake lever 2 to LOCK positions L to prevent the work equipment from moving Do not touch the control levers When it is necessary to operate the control levers always give a signal to your fel low workers to evacuate them to a safe place PRECAUTIONS...

Page 43: ...ght of the component Never use hydraulic jacks at places where the machine is damaged bent or twisted Never use if the element wire of wire rope is frayed twisted or pinched Never use bent or distorted hooks It is extremely dangerous to work under the machine if the track shoes are lifted off the ground and the machine is supported only with the work equipment If any of the con trol levers is touc...

Page 44: ...erated and may explode In addition the bat tery electrolyte includes dilute sulphuric acid Any mistake in handling may cause serious personal injury explo sion or fire so always observe the following Do not use or charge the battery if the battery electrolyte is below LOWER LEVEL mark This may cause an explosion Always perform periodic inspection of the battery electrolyte level and add purified w...

Page 45: ...ken pieces may be scattered and it may cause personal injury to the people in the surrounding area Always check that there is no one in the surrounding area If hard metal parts such as pins bucket teeth cutting edges or bearings are hit with a hammer pieces might be scattered and it may cause serious personal injury or death Always wear protective eyeglasses and gloves If the pin is hit with stron...

Page 46: ...contacts your skin or eyes directly If a jet of high pressure oil hit your skin or eyes and suffer injury wash the place with clean water and consult a doctor immediately for medical attention PRECAUTIONS FOR HIGH PRESSURE FUEL While the engine is running high pressure is generated in the engine fuel piping If you try to disassemble the piping before the internal pressure is released serious perso...

Page 47: ...for long periods of time wear ear covers or ear plugs while working If the noise is too loud it may cause temporary or permanent hearing problems PRECAUTIONS FOR HIGH PRESSURE GREASE WHEN ADJUSTING TRACK TENSION Grease is pumped into the track tension adjustment sys tem under high pressure If the specified procedure for maintenance is not followed when making adjustment grease drain plug 1 may fly...

Page 48: ...rogen gas so mistaken operation may cause an explosion which will lead to serious injury or death Always observe the following Do not disassemble it Do not bring it near flame or dispose of it in fire Do not make holes in it weld it nor use a cutting torch Do not hit or roll it or subject it to any impact When disposing of the accumulator the gas must be re leased Ask your Komatsu distributor to p...

Page 49: ...quid Methyl alcohol base washer liquid may irritate your eyes so do not use it PERIODIC REPLACEMENT OF DEFINED LIFE PARTS For using the machine safely for a long period always perform periodic replacement of the defined life parts that have a particularly close relation to safety such as hoses and the seat belt Replacement of the defined life parts See PERIODIC REPLACEMENT OF DEFINED LIFE PARTS Th...

Page 50: ...n tainer for storage Only open containers in a well ventilated area When storing DEF avoid direct sunlight Always use the original container it came in Do not exchange the con tainer of DEF with another one If DEF is stored in an iron or aluminum container toxic gas may develop and a chemical reaction may corrode the container PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE DEF is non flammable however in...

Page 51: ......

Page 52: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1 ...

Page 53: ...2 Angle cylinder 3 Front cover 4 ROPS cab 5 Sprocket 6 Idler 7 Work equipment frame 8 Tilt cylinder 9 Lift cylinder 10 Track frame 11 Track 12 Radiator grille 13 Komatsu Diesel Particulate Filter hereinafter KDPF 14 SCR GENERAL VIEW OPERATION 3 2 ...

Page 54: ...witch 2 Cigarette lighter 3 Fuel control dial 4 Joystick steering directional and gear shift lever 5 Rear lamp switch 6 Headlamp switch 7 Machine monitor 8 Foot heater switch 9 Engine shutdown secondary switch 10 Starting switch 11 Decelerator brake pedal 12 Blade control lever 13 Horn switch 14 Room lamp switch 15 Wiper switch 16 Parking brake lever 17 Work equipment lock lever OPERATION GENERAL ...

Page 55: ...t lamp 13 Work equipment lock pilot lamp 14 Aftertreatment devices regeneration pilot lamp or aftertreatment devices regeneration disable pilot lamp 15 Message display 16 Operating mode display 17 Steering mode display 18 Preheating pilot lamp 19 Fan reverse rotation pilot lamp 20 FLOAT mode pilot lamp 21 Blade mode display 22 Multi gauge 23 Fuel gauge 24 DEF level gauge 25 DEF level caution lamp ...

Page 56: ...INE MONITOR EQUIPMENT AA Standard screen EE Warning or Error screen DD Guidance screen 1 Warning display 2 Pilot display 3 Meter display 4 Speed range display 5 Monitor switch area 6 Guidance icon display REMARK If environmental temperature of the machine monitor is high brightness may be automatically reduced to protect the liquid crystal Intensity or color of the objects may change because of th...

Page 57: ... mode display screen HH After gear shift mode display screen HH is displayed for 2 seconds the screen switches to standard screen AA REMARK When the engine is started the battery voltage may suddenly drop depending on the temperature and the bat tery condition If this happens the machine monitor may restart but this does not indicate any abnormality BASIC OPERATION OF MACHINE MONITOR WHEN STARTING...

Page 58: ...SITUATION When the starting switch is turned to OFF position end screen JJ or KK is displayed for 5 seconds then the display goes out End screen when any message has been re ceived If there is any message from your Komatsu distributor it is dis played on the end screen In this case turn the starting switch to ON position to re check the message and if the message is requesting a response make a re...

Page 59: ...d clear an input character at a time On the ID number input screen LL with SKIP press switch F1 and the screen changes to the Check Before Starting screen BB without inputting ID number REMARK Contact your Komatsu distributor for details of the method of setting changing or canceling the operator identifica tion function Depending on the set value of ID holding time even if in putting ID number fo...

Page 60: ...a protec tion against theft it has no antitheft effect Be careful not to use it for the purpose of security enhance ment Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person OPERATION EXPLANATION OF COMPONENTS 3 9 ...

Page 61: ... before starting screen BB for 2 seconds the screen changes to the mainte nance time warning screen CC After displaying the maintenance time warning screen CC for 30 seconds the screen returns to the stand ard screen AA After displaying the check before starting screen BB for 2 seconds the screen changes to the warning screen FF 1 or error screen EE After displaying warning screen FF 1 for 2 secon...

Page 62: ...ny abnormality currently generated is displayed on top of switch F5 Press switch F5 to check the detail of the current abnormality The Current Abnormality screen is displayed OPERATION EXPLANATION OF COMPONENTS 3 11 ...

Page 63: ...y occurs during operation the standard screen AA changes to the abnormality screen EE If there is any error existing is displayed on top of switch F5 Press switch F5 to check the detail of the current abnormality The Current Abnormality screen is displayed EXPLANATION OF COMPONENTS OPERATION 3 12 ...

Page 64: ...ne coolant temperature caution lamp 6 Engine speed caution lamp 7 DEF level caution lamp 8 Fuel level caution lamp 9 Caution lamp Displayed items change according to setting of the multi gauge For details of the multi gauge see MULTI GAUGE Standard screen When 1 type of caution is generated it is displayed on caution lamp 2 When 2 types of cautions are generated they are displayed on caution lamps...

Page 65: ...s Degree of ur gency Action lev el Buzzer Caution lamp Required action High Low L04 Sounds contin uously Lights up in red Stop the machine immediately and ask your Komatsu distrib utor for inspection and maintenance L03 Sounds inter mittently Lights up in red Stop the operation and move the machine to a safe place then ask your Komatsu distributor for inspection and mainte nance L02 Sounds inter m...

Page 66: ...nceled In this case stop the machine and lower the engine speed to low idle with the fuel control dial or the decelerator brake pedal The engine output or engine speed limitation is reset Caution lamps and display colors Symbol Type of caution lamp Display color Machine condition Action level Red Yellow Blue White Engine coolant temperature cau tion lamp High temper ature L02 Normal Hydraulic oil ...

Page 67: ...ngine stop ped at high temperature L01 Engine system caution lamp Abnormal L04 L03 Abnormal L01 Parking brake system caution lamp Abnormal L04 L03 Abnormal L01 Fan control system caution lamp Abnormal L04 L03 Abnormal L01 Engine oil pressure caution lamp Low oil pres sure L03 Engine overrun caution lamp Overspeed L02 Charge level caution lamp Abnormal L03 HST oil filter clogging caution lamp Abnor...

Page 68: ...e Air cleaner clogging caution lamp Clogged L01 Maintenance time caution lamp Due time is over Notice Seat belt caution lamp Seat belt is not fastened For the meaning of each caution lamp and the action to take for it see the section of each caution lamp OPERATION EXPLANATION OF COMPONENTS 3 17 ...

Page 69: ...iate actions according to the displayed message Operation on the Current Abnormality screen On the Current Abnormality screen you can perform the fol lowing operations with switches F1 F2 and F5 F1 Displays the next page When on the last page it displays the first page F2 Displays the previous page When on the first page it dis plays the last page F5 Returns the screen to the standard screen EXPLA...

Page 70: ...icates action level L02 The hydraulic oil temperature is abnormally high Stop operations and stop the engine or run it at low idle until the caution lamp changes to the normal display color blue at an appropriate temperature When temperature is proper The caution lamp lights up in blue FUEL LEVEL CAUTION LAMP The fuel level caution lamp warns about low level of remaining fuel When fuel level is lo...

Page 71: ... work equipment system When action level L03 is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently Stop the operation move the machine to a safe place and then ask your Komatsu distributor for the inspection and main tenance When action level L01 is displayed The caution lamp lights up in yellow Some functions may be restricted from use but the machine can opera...

Page 72: ...peration always perform the inspection and maintenance Ask your Komatsu distributor for the inspection and maintenance as needed HST SYSTEM CAUTION LAMP HST system caution lamp warns about abnormality in the HST system When action level L04 is displayed The caution lamp lights up in red and the alarm buzzer sounds continuously Stop the machine immediately and ask your Komatsu distribu tor for insp...

Page 73: ...ING CAUTION LAMP HST oil filter clogging caution lamp warns about clogging of the HST oil filter When clogged The caution lamp lights up in red and action level L02 is dis played The alarm buzzer sounds intermittently HST filter is clogged Stop the engine and replace the HST oil filter cartridge with a new one For replacement of the filter element see METHOD FOR CHANGING OIL IN HYDRAULIC TANK REPL...

Page 74: ... that soot is accumulated in KDPF or the filtering function of KDPF has low ered abnormally To cancel the alarm perform the manual stationary regenera tion of KDPF When abnormal The caution lamp lights up in red and indicates action level L03 The alarm buzzer sounds intermittently Large accumulation of soot in KDPF or a system failure such as lowering of the filtering function of KDPF occurred Urg...

Page 75: ...immediately When Lightning in white When fluctuation of DEF tank level is large frozen or not limited to tank level sensing is not performed correct ly When DEF is added after engine starting switch turn to OFF When DEF tank level sensor is defective DEF SYSTEM CAUTION LAMP DEF system caution lamp alerts when abnormality in the sys tem are detected Whenever the caution lamp lights up in yellow or ...

Page 76: ... caution lamp lights up in red and the alarm buzzer sounds continuously Stop the machine immediately and ask your Komatsu distribu tor for inspection and maintenance When action level L03 is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently Stop the work move the machine to a safe place and then ask your Komatsu distributor for inspection and maintenance When a...

Page 77: ...icted for use but the machine can operate When you finish the operation always have the inspection and maintenance performed Ask your Komatsu distributor for inspection and maintenance as needed FAN CONTROL SYSTEM CAUTION LAMP The fan control system caution lamp warns about abnormality in the fan control system When action level L04 is displayed The caution lamp lights up in red and the alarm buzz...

Page 78: ...GE LEVEL CAUTION LAMP Charge level caution lamp warns about abnormality in the charging system while the engine is running When abnormal The caution lamp lights up in red and action level L03 is dis played The alarm buzzer sounds intermittently Charging is not performed normally while the engine is running Stop the engine and check the alternator drive belt for damage and then ask your Komatsu dis...

Page 79: ...er The caution lamp lights up in red The maintenance due time is over If no action is taken the machine performance will become worse and the machine life will be shortened Perform necessary maintenance as soon as possible When giving the notice of the due time The caution lamp lights up in yellow The maintenance due time is approaching Prepare necessary parts for the maintenance REMARK Check main...

Page 80: ...belt caution lamp lights up in red when the seat belt is not fastened It goes out when the seat belt is fastened For fastening the seat belt see METHOD FOR FASTENING AND UNFASTENING SEAT BELT OPERATION EXPLANATION OF COMPONENTS 3 29 ...

Page 81: ...ge 18 Engine coolant temperature gauge 19 Multi gauge 20 Fuel gauge 21 DEF level gauge 22 Fuel consumption gauge PILOT DISPLAY The pilot display at the top of the screen consists of the pilot lamps to check the actuation of each function When the starting switch is turned on and the display items are functioning the pilot lamps light up PREHEATING PILOT LAMP The preheating pilot lamp is displayed ...

Page 82: ... has been made OFF No messages OPERATING MODE DISPLAY The currently set operating mode is displayed on the operating mode display The display of the operating mode is as follows H For operations with emphasis on power Lights up when the mode is set to high engine idle speed mode P For heavy duty operations Lights up when the mode is set to power mode E For operations with emphasis on fuel consumpt...

Page 83: ...ces It goes out when the regeneration is completed AFTERTREATMENT DEVICES REGENERATION DISABLE PILOT LAMP Aftertreatment devices regeneration disable pilot lamp lights up when the post processing system is set not to be regenerated REMARK Even if the aftertreatment devices regeneration is disabled when the manual stationary regeneration is necessary KDPF soot accumulation caution lamp lights up If...

Page 84: ...anceled electronic sound of beep is heard BLADE MODE DISPLAY The currently set blade mode is displayed on the blade mode display The display of the blade mode is as follows A For fast operation Lights up when it is set to FAST mode B For general operation Lights up when it is set to NORMAL mode C For last leveling operation Lights up when it is set to FINE mode Press customize switch to set the bl...

Page 85: ...ch F5 is pressed Hydraulic relief deterrence guidance If the hydraulic oil is kept relieved for more than 10 seconds during operation the hydraulic relief deterrence message is displayed on the machine monitor The hydraulic relief deterrence message goes out 5 seconds later or when switch F5 is pressed E mode recommendation guidance If light load work is continued for more than 10 minutes in P mod...

Page 86: ...tion and the standard screen is displayed if the oper able time estimated from current DEF level and the latest average DEF consumption is shorter than 8 hours DEF low level message is displayed When the time until engine power deration starts is 1 to 8 hours Approx hours remaining to DEF refill caution is displayed When the time until engine power deration starts is less than 1 hour DEF refill ca...

Page 87: ...range display section indicates the following infor mation Bar graph A Lights up in accordance with the set speed in forward Bar graph B Lights up in accordance with the set speed in re verse C The travel speed range of the machine F1 for FOR WARD 1st R2 for REVERSE 2nd is displayed In variable shift mode the speed range is not displayed D The gear shift mode is displayed E Pedal mode is displayed...

Page 88: ...ations the overheat prevention system operates A to B Red range A to C Green range C to D White range The overheat prevention system is actuated as follows Red range A position Engine coolant temperature caution lamp E shows abnormality display Red range B position Engine speed changes to a medium speed engine coolant temperature caution lamp E shows abnormality display and alarm buzzer sounds at ...

Page 89: ...level hydraulic oil temperature caution lamp E shows abnormality display and alarm buzzer sounds at the same time The overheat prevention system continues to operate until the indicator enters the green range When the engine is started if the indicator is within white range C to D perform the warm up operation NOTICE When the indicator comes close to red range A during operation run the engine at ...

Page 90: ...lights up in red The correct fuel level may not be displayed for a short time after the starting switch is turned to ON position but this is not abnormal It does not indicate correct fuel level on the slopes Place the machine on a level ground and check the fuel level Check the fuel level on a level ground before operating on the slopes When operating the machine on the slopes for a long time move...

Page 91: ...f the engine speed By pressing switch F4 on the standard screen you can switch the clock display and service meter display REMARK If the battery is disconnected for a long period for storage etc the time information may be lost 12 hour or 24 hour system is available for clock display For details of setting and correction of time see CLOCK ADJUSTMENT Service meter display Clock display 12 hour disp...

Page 92: ...ent reduce the engine output to a point where there is no adverse effect on the operation Perform energy saving operations within the green range Travel less frequently It also helps energy saving op erations Consider the best way of operation for energy saving FUEL CONSUMPTION GAUGE Fuel consumption gauge shows the average fuel consumption of the machine A Shows the average fuel consumption of a ...

Page 93: ...he engine is running DEF level cau tion lamp 1 lights up in white However this does not indicate abnormality In cold weather DEF level cannot be detected and DEF level caution lamp 1 lights up in white for approxi mately 1 hour However this does not indicate abnormality Even if DEF level caution lamp 1 does not light up in white it may take a long time for DEF level gauge to display the correct po...

Page 94: ...nfirm the function of switches 1 by guidance icons 2 displayed on top of the switch While guidance icon 2 is not displayed switch 1 does not function even if it is pressed Even if guidance icon 2 is pressed it does not function Press function switch 1 directly under guidance icon 2 to operate the function When the monitor display shows the standard screen the types of guidance icons and functions ...

Page 95: ...ffer with the contents of the displayed screen but representative guidance icons frequently used and their functions are as follows G Switch F1 or F3 Moves to the left item When on the left end it moves to the right end H Switch F2 or F4 Moves to the right item When on the right end it moves to the left end I Switch F3 Moves to the item below forward When on the last line it moves to the first lin...

Page 96: ...ng item where there is an abnormality The buzzer cannot be stopped according to the content of the warning OPERATING MODE SELECTOR SWITCH The operating mode selector switch is used for switching the operating mode of the engine Normally it is possible to perform all operations in E mode and this mode reduces fuel consumption Compared with E mode P mode and H mode have more pow er but the fuel cons...

Page 97: ...ificing the speed of work equipment select the brake mode When the starting switch is turned to ON position the decelera tor mode is selected The selected mode is displayed at the top of the screen GEAR SHIFT MODE SELECTOR SWITCH The gear shift mode selector switch is used to switch the gear shift mode between quick shift mode and variable shift mode When the starting switch is turned to ON positi...

Page 98: ...Setting 1 0 1 2 3 5 levels Load Graph Dis play ON OFF Blade Mode FAST NORMAL FINE Steering Mode NORMAL FINE 1st Speed Setting 2 1 0 1 2 5 levels 2nd Speed Set ting 2 1 0 1 2 5 levels 3rd Speed Set ting 2 1 0 3 levels OPERATING MODE Select Operating Mode on Mode Select screen and press switch F6 Operating mode of engine can be switched in accordance with the operation Operating mode can also be swi...

Page 99: ...operation Reverse travel speed can also be set with the reverse travel speed setting switch LOAD DISPLAY Select Load Display on Mode Select screen and press switch F6 Display Non display of load graph can be switched Horizontal axis X indicates the time and vertical axis Y indi cates the drawbar pull in the load graph Similarly to the ECO gauge it is recommended to use in green range G The graphs ...

Page 100: ...rther from the position where the operating effort becomes large and the machine makes pivot turn When the starting switch is turned to ON position the normal mode is selected The selected mode is displayed at the top of the screen 1ST TRAVEL SPEED SETTING Select 1st Travel Speed Setting on Mode Select screen and press switch F6 1st travel speed in quick shift mode can be selected out of 5 levels ...

Page 101: ...You can increase or decrease the speed in 2 levels each 2 Increases 2 levels from preset 2nd travel speed 1 Increases 1 level from preset 2nd travel speed 0 Preset 2nd travel speed 1 Decreases 1 level from preset 2nd travel speed 2 Decreases 2 levels from preset 2nd travel speed For details of the travel speed setting method see 1ST TRAVEL SPEED SETTING EXPLANATION OF COMPONENTS OPERATION 3 50 ...

Page 102: ...ing method see 1ST TRAV EL SPEED SETTING METHOD FOR SETTING EACH ITEM AND SAVING MEMORY 1 Press switch F3 or F4 on Mode Select screen to set the yellow cursor to the target item of setting change and then press switch F6 The setting change screen for the selected item is dis played 2 Press switch F3 or F4 to move the yellow cursor to a set ting to change and press switch F6 The figure shows an exa...

Page 103: ...on METHOD FOR CALLING MEMORY 1 Press switch F1 on Mode Select screen The mode memory call screen is displayed 2 Press switch F3 or F4 to move the yellow cursor to a mem ory number M1 to M5 to call out As the cursor is set to the number the setting stored in the memory is displayed in the right side of the screen 3 Call out the selected setting by pressing switch F6 EXPLANATION OF COMPONENTS OPERAT...

Page 104: ...mera image is displayed it is possible to operate following modes It is possible to change the operating mode by pressing the operating mode selector switch When the operating mode is changed the screen returns automatically to the standard screen It is possible to change the gear shift mode by pressing the gear shift mode selector switch When the gear shift mode is changed the screen returns auto...

Page 105: ...y screen neither switches to another screen nor returns to the standard screen Depending on the warning alarm buzzer does not stop sounding by pressing the buzzer cancel switch Press the pedal mode selector switch to change the pedal mode When the pedal mode selector switch is pressed the screen returns automatically to the standard screen Actions against warning during camera image display If any...

Page 106: ...or 10 seconds or more the screen automatically returns to the standard screen When the screen returns to the standard screen the cau tion lamp at the top left of the screen goes out and an error or a warning is displayed at the center of the screen If an error is displayed move the machine set it in a safe posture then have inspection performed immediately OPERATION EXPLANATION OF COMPONENTS 3 55 ...

Page 107: ...ss switch F4 while the clock is displayed the service meter is displayed instead of the clock If you press switch F4 while the service meter is displayed the clock is displayed instead of the service meter MULTI GAUGE SELECTOR SWITCH Multi gauge display items can be switched by pressing the function switch F2 EXPLANATION OF COMPONENTS OPERATION 3 56 ...

Page 108: ... as fol lows Engine speed 1 500 rpm 2 1000 rpm 3 1500 rpm 4 2000 rpm 5 2750 rpm 6 3000 rpm 1 to 5 Green range 5 to 6 Red range During operation try to keep the pointer in green range Machine speed 1 0 km h 0 MPH 2 5 km h 3 1 MPH 3 10 km h 6 2 MPH 4 15 km h 9 3 MPH Work equipment pump pressure 1 0 MPa 0 kg cm2 0 PSI 2 10 MPa 102 kg cm2 1450 PSI 3 20 MPa 204 kg cm2 2900 PSI 4 30 MPa 306 kg cm2 4350 ...

Page 109: ... pointer is in red range charge during engine running is not performed normally Stop the operation move the machine to a safe place and then ask your Komatsu distributor for the inspection and maintenance Drawbar pull 1 0 W 2 0 2 W 3 0 4 W 4 0 6 W 5 0 8 W 6 1 0 W Clock display REMARK 12 hour or 24 hour system is available for clock display EXPLANATION OF COMPONENTS OPERATION 3 58 ...

Page 110: ...ng menu screens a Energy Saving Guidance b Machine Setting c Aftertreatment Devices Regeneration d SCR Information e Maintenance f Monitor Setting g Mail Check These menus a to g are for setting and confirming the fol lowing items For operations in each menu see the detailed explanation pa ges of respective items a Energy Saving Guidance Check of operating record Check of ECO guidance record Check...

Page 111: ...e Operation of manual stationary regeneration d SCR Information Check of DEF level Information on DEF system e Maintenance Check and reset of various maintenance times f Monitor Setting Screen Adjustment Screen Adjustment camera Clock adjustment Language selection ID key information Operator ID EXPLANATION OF COMPONENTS OPERATION 3 60 ...

Page 112: ... end menu it moves to the left end menu F3 Moves to the next item 1 line below When on the last line it moves to the first line on the next page F4 Moves to the previous item 1 line above When on the first line it moves to the last line on the previous page F5 Returns the screen to the standard screen F6 Displays the setting screen for selected item If no switch is operated for 30 seconds on the u...

Page 113: ...e Fuel Consump tion Actual Working Fuel Consumption Idling Hours and E mode time ratio on daily basis or on a split measurement peri od basis are displayed Operation on the Operation Records screen On Operation Records screen you can perform the following operations by pressing switch F3 to F5 F3 Displays the next page When on the last page it displays the first page F4 Displays the previous page ...

Page 114: ...rds screen F5 Returns the screen to the Energy Saving Guidance screen REMARK ECO guidance denotes displaying the guidance for energy sav ing operation This display may appear on the standard screen while the machine is in operation CHECK FUEL CONSUMPTION RECORD Select Average Fuel Consumption Record 3 on Energy Saving Guidance screen and then press switch F6 On Average Fuel Consumption Record scre...

Page 115: ...e of fuel consumption and fuel consumption rate may differ from the actual value due to the operating con ditions of the customers fuel used weather or work contents etc Switching of displayed graph Press F2 on Average Fuel Consumption Record screen to change the currently displayed graph to another REMARK There are 2 types of graphs One shows hourly average fuel consumption during last 12 hours a...

Page 116: ...ting of the Average Fuel Consumption Display Switching of the Display Non display of ECO gauge and drawbar pull gauge Setting of the ECO Gauge Display Fuel Target Value Switching of the Display Non display of the ECO Guidance Display Switching of the Display Non display of the ECO Guidance Display at Key OFF Operations on Configurations screen On Configurations screen it is possible to perform the...

Page 117: ...4 Moves to the previous item 1 line above When on the first line it moves to the last line on the previous page F5 Cancels the setting and returns to Configurations screen F6 Changes the setting and returns to Configurations screen 2 The Average Fuel Consumption Display screen appears 1 Day Displays the average fuel consumption from 0 00 a m of the day to 0 00 a m of the next day Split Time Displa...

Page 118: ... the Operation Records screen and the ECO Guidance Records screen When you stop the measurement select Operation Records 1 screen or ECO Guidance Records 2 screen on Energy Saving Guidance menu a Move to each screen press measurement stop switch F1 STOP OPERATION EXPLANATION OF COMPONENTS 3 67 ...

Page 119: ...ys ECO gauge B on the standard screen OFF Displays nothing on display 7 On this screen it is possible to perform the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line on the next page F4 Moves to the previous item 1 line above When on the first line it moves to the last line on the previous page F5 Cancels the settin...

Page 120: ... and press switch F6 2 ECO Gauge Display Fuel Target Value appears On this screen it is possible to perform the following oper ations with switches F3 to F6 F3 Decreases the target fuel consumption value by 1 ℓ h F4 Increases the target fuel consumption value by 1 ℓ h F5 Cancels the setting change and returns to Configura tions screen F6 Changes the setting and returns the screen to Configu ration...

Page 121: ...display ECO Guidance 10 on the stand ard screen On this screen it is possible to perform the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line on the next page F4 Moves to the previous item 1 line above When on the first line it moves to the last line on the previous page F5 Cancels the setting and returns to Configu...

Page 122: ...ECO Guidance 12 on the end screen OFF Does not display ECO Guidance 12 on the end screen On this screen it is possible to perform the following oper ations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Cancels the setting change and returns...

Page 123: ...everse operation is performed while aftertreat ment devices regeneration pilot lamp A is lit the engine speed may not increase even if the fuel control dial is set to High idle MAX position but this is not a failure If fan rotates in reverse with high speed for 10 minutes or more engine speed lowers automatically in order to pro tect the hydraulic component and the screen shown in the figure may b...

Page 124: ... side cover 7 Turn the starting switch to ON position 8 Select Fan Reverse Mode 1 on Machine Setting menu b screen 9 Press switch F6 If the parking brake lever or work equipment lock lever is in FREE position or the engine is running the screen shown in the figure is displayed and the fan rotation is not re versed 10 Press switch F6 when the fan reversing confirmation screen is displayed When canc...

Page 125: ... in the figure is displayed In this case stop the fan reverse rotation by returning the parking brake lock lever and work equipment lock lever to LOCK positions or by pressing switch F5 12 After finishing the work press switch F5 and stop the fan reverse rotation 13 Set the fuel control dial to Low idle MIN position 14 Turn the starting switch to OFF position to stop the engine EXPLANATION OF COMP...

Page 126: ...ess switch F6 2 Select the set time on the Auto Idle Stop Timer Setting screen shown and then press switch F6 On Auto Idle Stop Timer Setting screen it is possible to perform the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last li...

Page 127: ...p is activated only the engine is stopped and the machine monitor inverter etc as well as the electrical components including the air conditioner ra dio lamps and windshield wipers keep their states before the engine is stopped To prevent battery discharging turn the starting switch to OFF position 6 When restarting the engine turn the starting switch as usual EXPLANATION OF COMPONENTS OPERATION 3...

Page 128: ...ngs for the aftertreatment devices regeneration The operation methods and the contents of the display of KDPF regeneration and urea SCR regeneration are common SCR INFORMATION Each item in SCR Information menu d is for displaying the information related to SCR and DEF OPERATION EXPLANATION OF COMPONENTS 3 77 ...

Page 129: ...the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Returns the screen to the standard screen F6 If this switch is kept pressed the screen changes to the screen for resetting the remaining time to the main tenance for the selected item REMARK When resetting the remaining time to the maintenance keep switch F6 pressed for at least 1 5 second...

Page 130: ...he reconfirmation screen REMARK When canceling the reset press switch F5 The screen returns to Maintenance screen On Maintenance Due Time Reset screen if no switch is operated for more than 30 seconds the screen automatically changes to Maintenance screen 2 The reconfirmation screen is displayed If switch F6 is pressed again the remaining time is reset and the screen switches to Maintenance screen...

Page 131: ...o the Monitor Set ting menu screen F6 Accepts the change and returns to the Monitor Set ting menu screen REMARK If the light switch is at night mode ON and the screen is adjusted it is possible to adjust the brightness of the monitor screen night mode If the light switch is at day mode ON and the screen is adjusted it is possible to adjust the brightness of the monitor screen day mode As long as m...

Page 132: ...ra screen can be set Camera image screen brightness adjustment Camera view mode setting Setting of Reverse Synchroni zation Guide line display mode setting On this screen it is possible to perform the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line above When on the first line i...

Page 133: ...rse Synchronization setting 1 Select Camera View Mode on Screen Adjustment Cam era menu 2 Press switch F6 3 The Camera View Mode setting screen is displayed Normal Switch F2 of the function key is used to change the screen to the camera screen Reverse Synchronization Camera screen is auto matically displayed when the gear shift lever is set to reverse On this screen it is possible to perform the f...

Page 134: ...ne Only machine center line B is dis played All Both of Outline A and Center Line B are dis played On this screen it is possible to perform the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line above When on the first line it moves to the last line F5 Cancels the setting and retur...

Page 135: ...s F3 to F6 on Clock Adjustment screen GPS SYNCHRONIZATION SETTING On machines equipped with KOMTRAX turning on GPS Syn chronization menu enables automatic setting of the monitor s date and time in accordance with the clock of GPS F3 Moves to the next item 1 line below Moves to the top line when on the bottom line F4 Moves to the previous item 1 line above Moves to the bottom line when on the top l...

Page 136: ...en F6 Proceeds to setting for month 3 When month display B is highlighted in yellow operate the switches as follows to change month display B If it is not necessary to change the month press switch F6 F3 Calendar goes back 1 month F4 Calendar advances 1 month F5 Cancels change and returns to the year setting screen F6 Proceeds to setting for date 4 When date display C is highlighted in yellow oper...

Page 137: ... the screen to Clock Ad justment screen F6 Proceeds to setting for the minute 3 When minute display E is highlighted in yellow operate the switches as follows to change minute display E If it is not necessary to change the minute press switch F6 F3 The time goes back 1 minute F4 The time advances 1 minute F5 Cancels change and returns to the time setting screen F6 Accepts change and returns the sc...

Page 138: ... is turned off the clock display returns to the set time 1 Select Daylight Saving Time e on Clock Adjustment screen then press switch F6 2 The Daylight Saving Time screen is displayed F3 Moves to the next item 1 line below Moves to the top line when on the bottom line F4 Moves to the previous item 1 line above Moves to the bottom line when on the top line F5 Cancels change and returns to Clock Adj...

Page 139: ...uanian Bulgarian Greek Turkish Serbian 1 Select Language 4 on the Monitor Setting menu then press switch F6 2 Select the language to use for the display then press switch F6 The screen display changes to the selected lan guage On Language screen it is possible to perform the follow ing operations with switches F3 to F6 F3 Moves to the item below F4 Moves to the item above F5 Cancels change and ret...

Page 140: ...r details of the method of setting changing or canceling the operator identi fication function WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted the identified ID is displayed in the column of Operator ID on the Monitor Setting menu screen When the starting switch is ON and SKIP is selected is displayed in the column of Operator ID on th...

Page 141: ...u screen On the Monitor Setting menu screen as the same way when the starting switch is ON and SKIP is se lected is displayed in the column of Operator ID In this case the operator ID is not identified When you press switch F6 after inputting the ID which is not registered to the Operator ID Change screen a message is displayed below and the screen returns to the Monitor Setting menu screen In thi...

Page 142: ... screen and press F6 Then the identified ID can be changed A message is displayed below and the screen returns to the Monitor Setting menu screen When you press switch F6 after inputting the ID which is not registered to the Operator ID Change screen a message is displayed below and the screen returns to the Monitor Setting menu screen In this case the identified ID is not changed On the Operator ...

Page 143: ...s made OFF No messages REMARK When the message display lights up in blue B it means that no reply has been made yet to any read message to your Komatsu distributor Reply to the message in accord ance with the replying method mentioned below If the starting switch is turned to OFF position when there is any unread message the message will be displayed on the end screen and when the monitor is start...

Page 144: ...tion menu g The selected item number is written in place 5 of the message text Input the number by using the monitor panel switch Each switch corresponds to the value shown on the right side below the switch If you input an incorrect number press switch F5 and you can clear an input character at a time If switch F5 is pressed when the input column is blank the screen returns to the standard screen...

Page 145: ...e switch at this position while the engine is running C START position This is the position to start the engine Keep the key at this position during cranking and release it immediately after the engine starts When the switch is released it automatically returns to ON position B D HEAT preheating position This is the position to start preheating manually When the key is turned to HEAT preheating po...

Page 146: ...The position where the dial is turned fully to the right REMARK If the work is relatively low load operation and also does not require the high speed travel turn back the fuel control dial a little to Low idle MIN direction from High idle MAX position so that the fuel efficiency improves and the noise is reduced For last leveling operation or gravel spreading operation as well turn back the fuel c...

Page 147: ...half dry Foreign material caught in arm or blade Snow or ice sticking to arm or blade This switch is also used as the window washer switch The switch is operated as follows Switches LH FF RH and RR a ON position The wiper operates b Washer operating position While the switch is depressed the washing water is sprayed and wiper operates at the same time When the switch is released it returns to a po...

Page 148: ...ion is set to day mode C OFF position Lamps go out The monitor illumination is set to day mode REAR LAMP SWITCH Use the rear lamp switch to light up the rear lamp A ON position Rear lamp lights up B OFF position Rear lamp goes out ROOM LAMP SWITCH NOTICE If the room lamp is left to be turned on the batteries may be exhausted Always turn the switch to OFF position after using room lamp Use room lam...

Page 149: ...t the switch cover is closed and the switch is in the NORMAL position If not set it to the NOR MAL position 1 Raise cover C and open it 2 Turn the engine shutdown secondary switch to upper posi tion a and the engine stops a STOP ENGINE When abnormal switch is set to upper position b NORMAL When normal switch is set to lower position When cover C is closed the engine shutdown secondary switch autom...

Page 150: ...igh The lamp inside the switch lights up by operating the switch AIR CONDITIONER SWITCH Air conditioner switch is used to control the air conditioner A Air conditioning mode selector switch B Blower selector switch C Temperature control switch For details see HANDLE AIR CONDITIONER OPERATION EXPLANATION OF COMPONENTS 3 99 ...

Page 151: ...ves freely under external force REMARK The blade is not set in FLOAT mode until the lever is moved to LOWER stroke end To set the blade in FLOAT mode move the lever to LOW ER stroke end while pressing FLOAT button D When FLOAT mode is set the electronic sound of beep notifies that FLOAT mode is set After that if you release the blade control lever it returns to HOLD position B but FLOAT mode is ke...

Page 152: ...nd held in this position H RIGHT angle Blade is angled rightward REMARK If the angling operation is performed while the blade con trol lever is not in HOLD position while either or both of lifting and tilting operations are performed all of those op erations can be continued but the moving speed of the blade is lowered Select the operations according to the type of operation If the lifting or tilt...

Page 153: ... decelerator brake pedal and lower the engine speed ma chine may travel Be extremely careful of this on a downhill When driving down the slope select the speed range at which engine brake is effective and de press the decelerator brake pedal as needed The decelerator brake pedal is used to lower the engine speed or lower the travel speed to stop the machine Depress this pedal to lower the travel s...

Page 154: ...areful not to touch the joystick steering directional and gear shift lever When the parking brake lever is operated the brake is applied even in traveling Do not operate the parking brake lever in traveling except in emergency otherwise machine stops abruptly and it is dangerous The parking brake lever is the lever to control the parking brake Set it to LOCK position L and the parking brake is app...

Page 155: ...ment lock lever to LOCK position L When pulling up or pushing down the work equipment lock lever be careful not to touch the blade control lever The work equipment lock lever is a locking device of the blade When it is set to LOCK position L the TILT RAISE LOWER and FLOAT operations are locked When the work equipment lock lever is set to LOCK position L the blade control lever can be moved but bla...

Page 156: ...machine turns If the lever is tilted rightward or leftward until operating effort becomes large turning radius decreases from the one at loose turn REMARK When steering mode is NORMAL mode if lever is tilted to the position where the operating effort to right or left becomes large the machine makes pivot turn When steering mode is FINE mode even if lever is tilted to the position where the operati...

Page 157: ...ime this switch is pressed When the starting switch is turned to ON position the speed range is automatically set to 1st As the work load increases the travel speed gradually de creases and the gear is shifted down When the work load becomes light again the gear is shifted up to the set travel speed Even if gear is shifted down by automatic shifting speed range display does not change REMARK When ...

Page 158: ...raveling or performing operations If doors are left open they may be broken Keep the door locked open securely The doors may be closed by vibration SASH GLASS INTERMEDIATE LOCK When working with the cab sash glass open use this lock to prevent the glass from chattering When the lever is in FREE position F the glass can be opened or closed When the lever is in LOCK position L the glass is held in p...

Page 159: ...SHTRAY NOTICE While removing the ashtray if it is stuck in the console cover and hard to be removed open the lid of ashtray and then hold the ashtray body and twist it right and left to remove If you hold the lid of ashtray and twist it the ashtray may break This is on the left side of the operator s seat Always extinguish your cigarette before putting it in the ashtray and be sure to close the li...

Page 160: ...f this accessory socket 2 is 144W 12V x 12A When it is used at one place 144W 12V x 12 A When it is used at 2 places 144W in total REMARK Use this power source while engine is running Power source outside cab 24V power supply NOTICE Do not use this as a power supply for 12V equipment This will cause failure of the equipment Do not install equipment which exceeds 120W 24V x 5A Open the battery insp...

Page 161: ...uses protect the electrical component and wiring from burning out If the fuse becomes corroded or looks white powdery or the fuse is loose in the fuse holder replace the fuse Replace the fuse with the one of the same capacity Remove fuse box cover 1 under the left side of the operator s seat and fuse boxes A and B are seen Fuse box C is installed to the overhead panel EXPLANATION OF COMPONENTS OPE...

Page 162: ...ly 2 9 15 A Starting switch 10 30 A Engine controller 11 20 A Spare power supply 12 20 A Spare 13 5 A Key accessory engine 14 15 10 A Machine controller 2 16 10 A Monitor panel 17 5 A System operating lamp 18 10 A Service connector 19 10 A Continuous power supply for cab 20 10 A Key accessory Fuse box B No Fuse ca pacity Name of circuit 1 10 A Smart sensor relay 1 2 20 A Smart sensor relay 2 3 20 ...

Page 163: ... does not work or the pre heater does not work a fusible link built in the wiring harness is suspected to be disconnected Check and replace the fusible link Open the hydraulic tank inspection cover on the left side of the machine and then open the fusible link case cover and you see fusible links 1 and 2 Open the engine side cover on the right side of the machine and then open the fusible link cas...

Page 164: ...if equipped It can be installed at the rear part of the operator s seat Mounting bracket optional is necessary for installation For details of the parts necessary for installation consult your Komatsu distributor The directions are described on the nameplate affixed to the fire extinguisher Just in case carefully read and understand them beforehand FIRST AID KIT if equipped It can be installed at ...

Page 165: ...e battery When replacing fuse etc Do not turn battery disconnect switch to OFF position while the system operating lamp is lit If the battery disconnect switch is turned to OFF position while the system operating lamp is lit the data in the controller may be lost If this switch is turned to OFF position all the electrical system is cut out and the functions of KOM TRAX stop In addition the time in...

Page 166: ...e operating the battery disconnect switch check that lamp 1 is not lit NOTICE If the battery disconnect switch is turned off while this lamp is lit the data in the controller may be lost REMARK Even if the starting switch is in OFF position the controller may operate The lamp lights up in this case but it is not abnormal After the starting switch has been turned off the system operating lamp may s...

Page 167: ...ile open ing and closing the radiator grille When opening the radiator grille check that it is locked securely Check the lock and link part as well for abnormality Be careful not to hit your head etc against radiator grille when opening it Check the hose and piping which moves with radiator grille for crack and other damage METHOD FOR OPENING RADIATOR GRILLE 1 Remove bolts 1 2 pieces under the rad...

Page 168: ...ator grille without un locking it may break 1 Lift up the radiator grille and push lock releasing bar 2 to the direction of arrow Lock is released 2 Tighten bolts 1 2 pieces under the radiator grille DUST INDICATOR This device notifies the operator of clogging of air cleaner ele ment OPERATION EXPLANATION OF COMPONENTS 3 117 ...

Page 169: ...y Gray 2 ID key used to register or delete usual keys black 1 in or from the machine You cannot start the engine with this key NOTICE If you lose the registration key gray you cannot reg ister or delete the usual keys black Keep the regis tration key gray carefully If a registered key black is stolen or you lose it de lete it immediately You cannot start the engine with a usual key black if it is ...

Page 170: ... on the ma chine monitor When using a ID key keep it apart from the other ID keys You cannot start the engine with a key having no built in IC chip registration key gray or usual key black which is not registered in the machine If the ID key system has any abnormality the ID Key Sys tem Abnormality screen is displayed If this screen is dis played call your Komatsu distributor OPERATION EXPLANATION...

Page 171: ... currently in serted in the starting switch on the ID No display portion C in ID Key Information item B PROCEDURES FOR DISPLAYING ID NUMBERS OF ALL THE REGISTERED NOR MAL KEYS BLACK 1 Insert registration key gray in the starting switch and turn it to ON position and the ID Key Setting screen is dis played on the machine monitor 2 Press switch F6 and the ID No list of the registered ID keys normal ...

Page 172: ... displayed 2 Press switch F6 Yes on the Deletion of Registered Key screen and the confirmation screen for deletion of the reg istered key is displayed 3 Press switch F6 Yes again on the confirmation screen for deletion of the registered key and the registration is delet ed 4 When the registration is deleted the screen returns auto matically to the ID Key List screen Check that the ID No you select...

Page 173: ...e monitor 2 Turn the registration key gray to OFF position A and then to ON position B 5 times within 10 seconds accord ing to the direction shown on the screen REMARK If the operation of the starting switch is not finished within 10 seconds or the registration is not deleted normally the mes sage of Deletion of all the keys failed is displayed on the ma chine monitor If this screen is displayed r...

Page 174: ...mal key black to be registered and turn it to ON position B 3 The ID No of the normal key black currently inserted is displayed on the machine monitor and registration is com pleted When registering another normal key black at this time repeat the operation of step 2 REMARK You can register up to 255 normal keys black in the machine If normal keys are to the maximum the screen in the figure is dis...

Page 175: ...hich is registered al ready the screen in the figure is displayed REMARK If registration fails the screen in the figure is displayed If this screen is displayed repeat the registration procedure from the first EXPLANATION OF COMPONENTS OPERATION 3 124 ...

Page 176: ... regen eration pilot lamp 1 stays lit on the machine monitor REMARK Even if aftertreatment devices regeneration pilot lamp 1 lights up the machine does not need to be stopped and the work can be continued unless the caution lamp is displayed at the cen ter of the machine monitor During the regeneration of KDPF the temperature of KDPF or the engine room becomes high due to combustion of the soot Be...

Page 177: ...5 minutes Then stop the engine REMARK If the parking brake lever and work equipment lock lever are set to LOCK position the manual stationary regeneration may start automatically to protect the KDPF system If KDPF soot accumulation caution lamp 2 lights up in red the maximum engine output power and maxi mum engine speed are limited to protect the engine and KDPF system NOTICE If the work is contin...

Page 178: ...combustible matter which cannot be burnt by the regeneration is accumulated in the filter of KDPF the filter needs to be cleaned or replaced at regular intervals The engine speed or engine sound may change during or after the regeneration This is caused by the control for better regeneration and this is not a failure The smell of the exhaust gas is different from that of the conventional diesel en...

Page 179: ...ours If KDPF soot accumulation caution lamp 2 lights up in yellow stop the machine in a safe place after finishing the work and perform the manual stationary regeneration When the degree of emergency is high If KDPF soot accumulation caution lamp 2 lights up in red action level 3 L03 screen D is displayed If the parking brake lever and work equipment lock lever are set to LOCK position or joystick...

Page 180: ...ine with engine running 2 Check that there is no person or combustible matter around the machine particularly in the direction of the ex haust gas flow 3 Set the parking brake lever and work equipment lock lever to LOCK L position Unless they are set to LOCK position the manual station ary regeneration cannot be performed 4 Set the fuel control dial to Low idle MIN position 5 Press switch F6 to di...

Page 181: ...PF soot accumulation caution lamp is lit the accumulated soot may not be burnt sufficiently and the filtering function may not be improved Wait until the aftertreatment devices re generation pilot lamp or the KDPF soot accumulation cau tion lamp goes out and then perform hydraulic fan reverse operation REMARK The explanation of the manual stationary regeneration is displayed in 3 parts on the mach...

Page 182: ... even when the soot accumula tion level is 0 to 3 In this case the soot accumula tion level may not decrease but this is not trouble The progress is not displayed on the machine monitor during this regeneration It is completed in approxi mately 10 minutes If the parking brake lever and work equipment lock lever or the fuel control dial is operated during the manual stationary regeneration the rege...

Page 183: ... lights up move the ma chine to a safe place and perform manual stationary regen eration If the operation is continued without performing the man ual stationary regeneration it may cause the failure of KDPF or the engine While regeneration is not being performed Setting for regeneration disable When aftertreatment devices regeneration pilot lamp is lit on the standard screen 1 On the standard scre...

Page 184: ...p 3 may light up but this does not indi cate abnormality Also during the regeneration to protect the system the regeneration disable cannot be operated When the regeneration is performed to protect the system the exhaust temperature is lower than that of when the re generation is performed to burn soot and is almost the same level as the normal exhaust gas temperature While regeneration is being p...

Page 185: ... Regeneration screen is dis played If the Aftertreatment Devices Regeneration screen is not displayed display it by operating switches F1 and F2 2 Select Cancel of Regeneration Disable and press switch F6 and the regeneration disable is canceled If soot accumulation level 4 is lit 3 or more the regenera tion is started automatically REMARK When performing the cancel of regeneration disable set the...

Page 186: ... the engine is operated without KCCV filter element or if a filter element other than the Komatsu genuine element is used the engine sucks oil and foreign ma terial which can cause a failure Always install Komat su genuine KCCV filter element The filter element cannot be flushed Never reuse the filter element since it can cause a performance decre ment of engine and it result in a failure even if ...

Page 187: ...f potential degradation of nitrogen oxides conversion efficiency are detected the active regenera tion is triggered to rejuvenate Urea SCR system even if the amount of soot accumulated in the KDPF has not reached to the regeneration thresholds k k WARNING Fill ONLY DEF into DEF tank Foreign material in the DEF system or urea deposits caused by evaporation may hin der operation of the devices NOTIC...

Page 188: ...ment strategy will be activated If Inducement starts add DEF to the DEF tank immediately The DEF level caution lamp 1 on the monitor lights up the audible alert starts and the Action level is dis played and Inducement strategy is activated Inducement strategy includes engine output deration speed limi tation or other warning actions intend to prompt the operator to maintain or repair SCR system Th...

Page 189: ...n lamp 1 lights up in red No audible alert No Action level is displayed Press F6 to display the SCR Information screen Inducement status 4 1 DEF low level warning appears Add DEF to the DEF tank immediately Escalated Warning The audible alert sounds in repetition of three beeps and a pause 2 gradations of the DEF level gauge light up in the red range DEF level caution lamp 1 lights up in red No Ac...

Page 190: ... 4 Engine power is under heavy de ration The remaining time Hour and minute to the Final Induce ment is displayed in the column 6 of the SCR Informa tion screen If no DEF is added during the Severe In ducement Inducement advances to Final Inducement within 1 hour At Final Inducement engine speed is fixed at low idle Engine power can be restored temporarily from power derate This engine power resto...

Page 191: ...nducement The Inducement strategy includes vis ual alert by the DEF system caution lamp 1 and Action Level displayed on the machine monitor 2 and the audible alert by a buzzer and stepwise engine power deration that advances to speed limitation to low idle Engine power deration starts with Action Level L03 Mild Inducement and advances to further deration when L04 Severe Inducement and Final Induce...

Page 192: ... actions instructed by the Action Level table Inducement advances to Escalated Warning Escalated Warning The audible alert sounds in repetition of three beeps and a pause The DEF system caution lamp 1 lights up in yellow If operation continues for 1 hour after Warning started without taking any actions instructed by the Action Level table Inducement advances to Escalated Warning Press F6 to displa...

Page 193: ...ssage 4 4 Engine power is under heavy deration Due to the further deration of engine power capability the machine will be limited further Move the machine to the safe place and contact your Ko matsu Distributor The duration of Severe Inducement is 1 hour The re maining time Minutes to Final Inducement is displayed in the column 5 of the SCR Information screen In Final Inducement engine speed will ...

Page 194: ...ducement Severe Inducement and Final Inducement The Inducement strategy includes vis ual alert by the KDPF System caution lamp 1 DEF system caution lamp 2 and Action Level displayed on the machine monitor 3 audible alert by a buzzer and stepwise engine power deration that advances to speed limitation to low idle Engine power deration starts with Action Level L03 Mild In ducement and advances to fu...

Page 195: ...SCR system Engine power is derated Move the machine to the safe place and contact your Ko matsu Distributor If operation continues for 1 hour after Warning started without taking any actions instructed by the Action Level table Inducement advances to Escalated Warning Escalated Warning The audible alert sounds in repetition of three beeps and a pause The KDPF system caution lamp 1 lights up in red...

Page 196: ...ction level display 3 Press F6 to display the SCR Information screen SCR Information screen message 5 4 Engine power is under heavy deration Due to the further deration of engine power capability the machine will be limited further The duration time of Severe Inducement is 1 hour The remaining time Minutes Final Inducement is displayed in the column 6 of SCR Information screen In Final Inducement ...

Page 197: ...nt through the machine monitor Note that Temporary Restoration from Inducement does not regain full engine power Temporary Restoration from Inducement can be activated only when the Urea SCR system is in Severe In ducement The maximum duration is limited to 30 minutes in each restoration operation and 3 operations are allowed but Temporary Restoration from Inducement is turned off whenever the sys...

Page 198: ... window B 4 Press F6 while the Engine power Recovery window is displayed Temporary Restoration from Inducement is activated and engine power deration is relieved to the deration of Mild Inducement for the maximum of 30 minutes as long as there is sufficient remaining time to Final Inducement Note that whenever Inducement advances to Final In ducement Temporary Restoration from Inducement will be t...

Page 199: ...0 hours after the previous abnormalities were corrected regardless of the level of the previous Inducement and whether the new abnormality abnormalities is the same as the previous ones or not it is judged as a recurrence If a recurrence occurs Severe Inducement will be activated If this occurs utilize Temporary Restoration from Inducement and move the machine to a safe place and contact your Koma...

Page 200: ...tsu genuine parts foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine Never operate the machine without DEF filter attached nor use the filter other than Komatsu genuine parts DEF filter cannot be flushed Flushing or regenerating of it will degrade the performance of DEF filter and will contaminate DEF pump and DEF injector which will cause the failur...

Page 201: ...nagement is gathered from the inside network of the machine It can be useful for you to perform the machine management by yourself Your Komatsu distributor uses the above ma chine information for supply of service to the customers improvement of our products and service etc The type of information which is sent from the machine may vary depending on the machine For the radio sta tion establishment...

Page 202: ...heck for dirt accumulated around the engine and radiator Also check for combustible materials dry leaves twigs etc around the battery exhaust pipe aftertreatment devices turbocharger or other high temperature engine parts If any dirt or combustible materials are found remove them 3 Check around the engine for leakage of coolant oil and air Check for oil leakage from the engine coolant leakage from...

Page 203: ...tsu distributor for repair 13 Remove dirt from around the aftertreatment devices Check the space around the aftertreatment devices for accumulated dirt and combustible materials dry leaves and twigs If any dirt or combustible materials are found remove them 14 Check around the aftertreatment devices for exhaust gas leakage Check the pipe between the KDPF and turbocharger and also the KDPF connecti...

Page 204: ... METHOD FOR CHECKING WATER SEPARATOR DRAINING WATER AND SEDI MENT The water separator serves to separate water mixed in the fuel Prepare a container to catch the water and sediment 1 Open the engine side cover on the left side of the ma chine The water separator is in one piece with fuel prefilter 1 and located in the lower part 2 Check the water level and sediment through transparent cup 2 3 If w...

Page 205: ...l above H line It may damage the oil circuit and cause the oil to spurt out Set the work equipment to the posture shown in the figure be fore checking hydraulic oil level or adding oil 1 Place the machine on a level ground and lower the work equipment to the ground If the machine is inclining make it level 2 Stop the engine 3 Wait for approximately 5 minutes and then open the hydraulic tank inspec...

Page 206: ...l changes depending on the oil tempera ture Use the following as guide line Before starting operation Between H and L marks oil temperature 10 to 30 C 50 to 86 F During normal operation Around H mark oil tempera ture 50 to 80 C 122 to 176 F After adding oil close the cap securely and always lock with key OPERATION MACHINE OPERATIONS AND CONTROLS 3 155 ...

Page 207: ...olant is insufficient Add coolant to FULL level through the filler port of reservoir tank 1 REMARK The coolant may overflow from the reservoir tank drain hose This is no problem It occurs because too much coolant has been added After adding tighten the cap securely 3 Check reservoir tank 1 for abnormality If reservoir tank 1 is empty leakage of coolant should be suspected 4 If reservoir tank 1 has...

Page 208: ... However if the coolant level is normal it is not a problem Prepare a container to catch drained oil 1 Open the engine side cover on the left side of the machine 2 Open the cap of oil filler port F 3 Pull out dipstick G and wipe off the oil with a cloth 4 Insert dipstick G fully into the dipstick pipe and pull it out 5 Check if the oil is sticking up to between marks H and L on dipstick G When the...

Page 209: ...he engine oil put a container to catch the oil under hose 2 4 Check the oil level again 6 After the oil is adjusted to a proper level insert dipstick G fully into the dipstick pipe again 7 Tighten the cap of oil filler port F securely 8 Close the engine side cover MACHINE OPERATIONS AND CONTROLS OPERATION 3 158 ...

Page 210: ...rt circuiting on the electrical wiring promptly ask your Komatsu distributor to locate the cause of it and to perform the repair Keep the top surface of the battery clean and check the vent hole in the battery cap If it is clogged with dirt or dust wash the battery cap with water to clear the vent hole NOTICE In particular inspect the wiring of battery starting motor and alternator with care Perfo...

Page 211: ...vent the engine from sucking in air pay careful attention to the amount of fuel remaining in the tank 1 Turn the starting switch to ON position B 2 Check the remaining level by the fuel gauge on the ma chine monitor When the pointer is in green range a to c The fuel level is proper When the pointer is in red range a to b The fuel is insufficient Turn the starting switch back to OFF position A and ...

Page 212: ...3 After checking turn the starting switch back to OFF posi tion A OPERATION MACHINE OPERATIONS AND CONTROLS 3 161 ...

Page 213: ...than line 7 of sight gauge 3 Be careful of the DEF line to be added when performing operations on a slope or traveling on a rough ground When the remaining DEF level is low a warning may be displayed or the engine out put power limitation may be activated if DEF pump sucks air or if DEF level suddenly drops If DEF is stored in another container foreign material may mix in it and toxic gas or corro...

Page 214: ...VER 2 Turn the DEF tank filler port cap 2 counterclockwise O and open it Direction of O Open Direction of C Close 3 While watching sight gauge 3 add DEF through filler port 2 until float 4 reaches F line 5 Line 6 in the sight gauge indicates approximately 5 ℓ 1 32 U S Gal below F line and line 7 indicates ap proximately 10 ℓ 2 64 U S Gal below F line Line 7 is the adding line when DEF may freeze i...

Page 215: ...he tank cancels the wrong fluid addition prevention device and you can add DEF This mechanism prevents addition of DEF into the fuel tank addition of fuel into DEF tank and spill of DEF from the filler port When using a nozzle which is not conformed to ISO 22241 4 hold it in your hand and add DEF carefully while checking the sight gauge If it is difficult to see the sight gauge due to dirt etc re ...

Page 216: ... lean on the opened DEF tank filler port cover BIB container 10 ℓ approximately 2 5 U S Gal weighs 11 kg 24 255 lb Before putting the BIB container on the DEF tank filler port cover put it on the track first Then climb on the top of the track from the front of the machine and move the BIB container to the top of the DEF tank filler port cover Prepare a BIB container 10 ℓ approximately 2 5 U S Gal ...

Page 217: ...and open it Direction of O Open Direction of C Close 9 Insert the bellows hose of the BIB container into filler port 2 If it is difficult to insert the bellows hose into filler port 2 make the end of the BIB container a and b as fulcrum and lift up the other end of BIB container to perform the work MACHINE OPERATIONS AND CONTROLS OPERATION 3 166 ...

Page 218: ...line F and line 7 indicates approxi mately 10 ℓ 2 64 U S Gal below line F Line 7 is the adding line when DEF may freeze in cold weather 11 Close the DEF tank filler port cap 2 by turning it clockwise C Align the claw 8 of the cap with groove 9 of the filler port and close the cap securely by turning it clockwise by 90 OPERATION MACHINE OPERATIONS AND CONTROLS 3 167 ...

Page 219: ...e rear lamp switch to ON position d and check that the rear lamp lights up If the lamps do not light up a broken bulb or disconnected wire are the possible causes Ask your Komatsu distributor for repairs 4 After finishing the check turn the head lamp to OFF posi tion c and turn the rear lamp to OFF position e 5 Turn the starting switch to OFF position A MACHINE OPERATIONS AND CONTROLS OPERATION 3 ...

Page 220: ...may have an open circuit Ask your Komatsu distributor for the inspection METHOD FOR REMOVING DEPOSIT IN ENGINE COMPARTMENT Check that there is no deposit inside the engine compartment particularly around the turbocharger exhaust manifold and aftertreatment devices If there is any deposit remove it METHOD FOR CHECKING HORN OPERATION 1 Turn the starting switch to ON position B 2 Check that the horn ...

Page 221: ...3 Return the starting switch back to OFF position A MACHINE OPERATIONS AND CONTROLS OPERATION 3 170 ...

Page 222: ...on R The alarm must sound immediately at this time The alarm keeps sounding until the joystick steering di rectional and gear shift lever is set to NEUTRAL position N or FORWARD position F 4 After checking the alarm operation return the joystick steering directional and gear shift lever to NEUTRAL po sition N immediately 5 Return the starting switch back to OFF position A OPERATION MACHINE OPERATI...

Page 223: ...erator brake pedal can be fully depressed AIR SUSPENSION SEAT LOW BACK SEAT METHOD FOR ADJUSTING SEAT IN FORE AND AFT DIRECTION 1 Pull up the fore aft adjustment lever and set the seat to the desired position Fore and aft adjustment range 180 mm 7 1 in 18 steps 2 After adjusting release the lever METHOD FOR RECLINING SEAT The reclining of the seat becomes large when the seat is moved forward and i...

Page 224: ...ince such practice can damage the air com pressor The seat height is adjusted pneumatically and in stepless 1 Pull up lever 1 fully or push it down fully to adjust the seat height For adjusting the seat height pull up lever 1 to make the seat higher and push it down to make the seat lower Adjust it so that the weight adjustment indicator 2 enters the green range You can adjust the height by operat...

Page 225: ...D FOR HEATING SEAT Turn on the seat heater switch a OFF position b ON position The backrest and seat surface are heated When the seat heater switch is turned on the heater in the seat operates When the seat surface temperature exceeds approximately 20 C 68 F the heater is turned off automatically When the temperature decreases below approximately 10 C 50 F the heater is turned on automatically REM...

Page 226: ...justment lever and set the seat back to a position which is comfortable for operation Foremost reclining Approx 66 Approx 1 9 x 35 steps Rearmost reclining Approx 72 Approx 1 9 x 38 steps Sit with your back against the backrest when adjusting If your back is not touching the backrest it may suddenly move forward 2 After adjusting release the lever METHOD FOR TILTING SEAT Pull up the tilt adjustmen...

Page 227: ...is moved backward turn knob 1 to adjust Weight adjustment range 60 to 150 kg 132 to 330 lb 2 After adjusting the weight return the crank of knob 1 2 Adjust the height by turning knob 1 in the green range The seat height is increased by turning the knob clockwise R seeing from the seated position and de creased by turning the knob counterclockwise L Vertical adjustment range Stepless 75 mm 3 in 3 A...

Page 228: ...D FOR HEATING SEAT Turn on the seat heater switch a OFF position b ON position The backrest and seat surface are heated When the seat heater switch is turned on the heater in the seat operates When the seat surface temperature exceeds approximately 20 C 68 F the heater is turned off automatically When the temperature decreases below approximately 10 C 50 F the heater is turned on automatically REM...

Page 229: ...and set the seat back to a position which is comfortable for operation Forward reclining Approximately 20 Backrest becomes free at 20 and above Backward reclining Approximately 60 Sit with your back against the backrest when adjusting If your back is not touching the backrest it may suddenly move forward 2 After adjusting release the lever METHOD FOR TILTING SEAT 1 Pull up the tilt adjustment leve...

Page 230: ...spen sion may be released After the automatic weight based adjustment the seat is the lowest position in the adjustment range Adjust the height of the seat METHOD FOR ADJUSTING SEAT HEIGHT Turn the engine starting switch to ON position when performing adjustments of seat height since the air com pressor built in the seat is used for this adjustment NOTICE Avoid using the height adjustment lever co...

Page 231: ...support while keeping the staring switch in ON position Press the adjustment switch to give proper tension to the waist part Press side Tension of backrest increases Press side Tension of backrest decreases Adjust the curve of backrest to your desired shape METHOD FOR ADJUSTING DAMPER Turn the adjustment knob to adjust the hardness of damper to the desired level Turn to direction L Damper is harde...

Page 232: ...r 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 METHOD FOR ADJUSTING ARMREST The R H and L H armrests of the operator s seat can be adjusted in height in 3 levels After adjusting the oper ator s seat adjust them to proper height 1 Loosen bolts 1 on the R H and L H of the operator s seat 2 places each 2 Adjust the R H a...

Page 233: ...LT Check for looseness of the mounting bolts of the metal fittings which are installing the seatbelt to the machine If they are loosened retighten them Tightening torque 25 5 Nm 2 5 0 5 kgm 18 1 3 6 lbft NOTICE If the seatbelt has flaw fuzz breakage or deformation after long time use replace it METHOD FOR FASTENING SEAT BELT Sit on the seat depress the decelerator brake pedal fully and adjust the ...

Page 234: ...G SEAT BELT 1 Press button 2 in buckle 1 and remove tongue 3 from buckle 1 2 Hold grip 4 and slowly return the belt into retractable de vice 5 The belt retracts automatically OPERATION MACHINE OPERATIONS AND CONTROLS 3 183 ...

Page 235: ...at always set parking brake lever 1 and work equipment lock lever 4 to LOCK position regardless of whether the engine is running or stopped 1 Check that battery disconnect switch S is in ON position I 2 Check that parking brake lever 1 is in LOCK position L If parking brake lever 1 is not in LOCK position L the engine cannot be started 3 Check that joystick steering directional and gear shift lev ...

Page 236: ...ed 7 Turn fuel control dial to Low idle MIN position When the dial is in High idle MAX position be sure to set it to Low idle MIN position REMARK Even if the engine is started with the fuel control dial in a position other than Low idle MIN position the engine speed is set to low idle speed You can change the engine speed by turning the fuel con trol dial to Low idle MIN position and then turning ...

Page 237: ...approximately 2 seconds Hydraulic oil temperature gauge 5 Engine coolant temperature gauge 6 Engine oil pressure caution lamp 7 Charge level caution lamp 8 Multi gauge 9 Fuel gauge 10 Speed range display 11 If any caution lamp does not light up or the buzzer does not sound there is probably a failure in the machine monitor so ask your Komatsu distributor for repair 3 Check that the screen changes ...

Page 238: ...intenance time caution lamp 15 is lit press switch F6 to check the item and perform the maintenance immediately If the maintenance time has passed for certain items maintenance time caution lamp 15 is lit for 30 seconds For details of the method of checking the maintenance in terval see MAINTENANCE SCREEN SETTING OPERATION MACHINE OPERATIONS AND CONTROLS 3 187 ...

Page 239: ...sly for more than 60 seconds in any case If the engine does not start wait for approximately 2 minutes then repeat the procedure from step 2 When starting the engine if the fuel control dial is at High idle MAX position the engine will accelerate suddenly and cause damage to the engine parts Before starting the engine check that fuel control dial 1 is at Low idle MIN position This machine is equip...

Page 240: ...charged for a short time immediately after the engine is started or during the after treatment devices regeneration in the cold season but this is not a failure The smell of the exhaust gas is different from that of the conventional diesel engine because of the exhaust gas filtering function OPERATION MACHINE OPERATIONS AND CONTROLS 3 189 ...

Page 241: ...o not turn the starting motor continuously for more than 60 seconds in any case If the engine does not start wait for approximately 2 minutes then repeat the procedure from step 2 When starting the engine if the fuel control dial is at High idle MAX position the engine will accelerate suddenly and cause damage to the engine parts Before starting the engine check that fuel control dial 1 is at Low ...

Page 242: ...er preheating pilot lamp 3 goes out turn the key of starting switch 2 to START position C and start the en gine 6 When the engine starts release the starting switch key 2 The key will return automatically to ON position B REMARK Just after starting the engine run it at low idle During this period release the decelerator brake pedal and perform no operation of the work equipment 7 When the engine s...

Page 243: ...ction and automatic warm up function operate at the same time the turbo protect function is given priority When the turbo protect function is actuated the engine speed is held at 1000 rpm even if the fuel control dial is turned to a position of 1000 rpm or higher When the turbo protect function is canceled the engine speed is set to the speed for the position of the fuel control dial The relations...

Page 244: ...ondition continues the engine may be dam aged In that case ask your Komatsu distributor to check the engine as soon as possible METHOD FOR CHECKING LOW SPEED RUN AND ACCELERATION OF ENGINE k k CAUTION Perform these checks in a safe place watching out for danger in the surroundings When the engine performs very badly at low idle and in the acceleration and if that condition contin ues it may damage...

Page 245: ...t perform operations or operate the levers sharp ly while the hydraulic oil is at low temperature Always perform the warm up operation until the hydraulic oil temperature caution lamp shows the green display This will extend the service life of the machine Do not accelerate the engine abruptly until it is warmed up Do not run the engine at low idle or full throttle with no load for 20 minutes and ...

Page 246: ...less after the engine is started the warm up operation starts auto matically The automatic warm up operation stops when the engine cool ant temperature increases the specified temperature 30 C 86 F or after warm up operation of 10 minutes even if the coolant temperature does not increase to 30 C 86 F After the automatic warm up operation if the engine coolant temperature or hydraulic oil temperatu...

Page 247: ...troke end and hold it with your hand for 1 minute 8 3 minutes later set blade control lever 2 to RAISE position a and release FLOAT 9 After the warm up operation check that each gauge and caution lamp indicate the normal values If any problem is found perform maintenance or repair 10 Operate the machine under light load until the engine cool ant temperature gauge and hydraulic oil temperature gaug...

Page 248: ...treatment devi ces regeneration the components may be damaged Stop the regeneration first then stop the engine as fol lows When the engine is stopped during or just after the af tertreatment devices regeneration is finished the parts around aftertreatment devices may become high tem perature Take care 1 Lower the work equipment to the ground 2 Turn fuel control dial 1 to Low idle MIN position 3 Ru...

Page 249: ...ition A while the engine is still hot guidance 3 may be displayed on the machine monitor To cool down the engine before stopping run it at low idle the next time and after because it may cause damage to the devi ces After the engine is stopped DEF in DEF injector and pump is automatically purged and returned to the tank to prevent malfunction of the devices caused by freez ing of DEF or deposition...

Page 250: ...ine at full speed Depress decelerator brake pedal 2 fully select 1st speed and set joystick steering directional and gear shift lever 4 to the direction to move off Begin to release decelerator brake pedal 2 gently and when the machine moves off slowly or shoe slip release decelerator brake pedal 2 fully When decelerator brake pedal 2 is depressed or fuel control dial 3 is set in Low idle MIN posi...

Page 251: ... 6 Set the joystick steering directional and gear shift lever 4 to FORWARD position F or REVERSE position R REMARK Check that the backup alarm sounds when the joystick steering directional and gear shift lever is set to RE VERSE position If the alarm does not sound ask your Ko matsu distributor for repair 7 Turn fuel control dial 3 to High idle MAX position MACHINE OPERATIONS AND CONTROLS OPERATIO...

Page 252: ...g decelerator brake pedal 2 gradually REMARK When moving off the machine sometimes deviates a little but this is due to actuation of straight travel correction mechanism and it is not a failure OPERATION MACHINE OPERATIONS AND CONTROLS 3 201 ...

Page 253: ...t the work equipment into the ground If the blade control lever is touched by accident the blade may suddenly move and this may lead to a seri ous accident Before leaving the operator s seat al ways secure work equipment lock lever 2 in LOCK position 1 Depress decelerator brake pedal 3 2 Return joystick steering directional and gear shift lever 4 back to NEUTRAL position N The machine stops To kee...

Page 254: ...1 step each time this switch is pressed DOWN switch D The speed range is shifted down by 1 step each time this switch is pressed When the starting switch is turned to ON position speed range is automatically set to 1st speed METHOD FOR CHANGING GEARSHIFT MODE In the gear shift mode quick shift mode and variable shift mode are available Select the mode to match the use For the use see FEATURES OF W...

Page 255: ... F FORWARD R REVERSE Speed range display F 1 1st 2 2nd 3 3rd Example In case of FORWARD 2nd F2 When the directional condition is NEUTRAL N is displayed between the directional display E and speed range display F When the parking brake is being applied P is displayed between the directional display E and speed range display F Upper bar graph G lights up in accordance with the set travel speed in fo...

Page 256: ...ights up in accordance with set travel speed in forward Lower bar graph H lights up in accordance with set travel speed in reverse When the starting switch is turned from OFF to ON position the speed range is set to 1st speed When switching from variable shift mode to quick shift mode the speed range becomes nearest one among 1st 2nd and 3rd For the lighting up of bar graph G and H and set travel ...

Page 257: ...fficiency in dozing operation increase the reverse travel speed When traveling in reverse on the rough ground or dozing uphill decrease the reverse travel speed Reverse travel speed can be set with reverse travel speed setting switch A and B Each time switch A is pressed the set travel speed in creases Each time switch B is pressed the set travel speed de creases Lower bar graph H indicates the re...

Page 258: ...dal to lower the engine speed 1 Depress decelerator brake pedal 1 to reduce the engine speed 2 Set joystick steering directional and gear shift lever 2 to a desired position Position F FORWARD Position N NEUTRAL Position R REVERSE Check that the backup alarm sounds when the joystick steering directional and gear shift lever is set to RE VERSE If the alarm does not sound ask your Komatsu distributo...

Page 259: ... steering di rectional and gear shift lever 1 is tilted METHOD FOR TURNING THE MACHINE WHILE TRAVELING FORWARD When gradually turning to the left tilt the joystick steering di rectional and gear shift lever forward and tilt it to left L half way Any turning radius can be set until the operating effort of joy stick steering directional and gear shift lever becomes large REMARK When gradually turnin...

Page 260: ...de is set to the fine mode the machine cannot make counter rotation turn 1 Check that the steering mode is set to the normal mode When the steering mode is not set to the normal mode set it to the normal mode according to the following procedure 1 Press the switch F1 on the standard screen to display Mode Select screen 2 On Mode Select screen select Steering Mode and press the switch F6 3 On Steer...

Page 261: ...he point where the joystick operating effort becomes large The R H and L H tracks rotate in the opposite directions to each other to make counter rotation turn on that place REMARK To make counter rotation turn to the right operate the joy stick steering directional and gear shift lever to the right in the same manner MACHINE OPERATIONS AND CONTROLS OPERATION 3 210 ...

Page 262: ...r shift lever forward and tilt it to left L half way Any turning radius can be set until the operating effort of joy stick steering directional and gear shift lever becomes large Cross steering does not occur REMARK When gradually turning to the right tilt the joystick steering di rectional and gear shift lever forward and tilt it to right halfway OPERATION MACHINE OPERATIONS AND CONTROLS 3 211 ...

Page 263: ...ations are needed Use this mode for pushing down operations and grading operations where power is not needed H High engine idle speed mode Engine high idle speed is set higher compared with P mode and it is easy to control the load Fuel consumption becomes larger than P mode Pedal mode Pedal mode can be changed with pedal mode selector switch 3 Pedal mode Features Decelerator mode Depress the dece...

Page 264: ...ing in reverse and the machine starts counter rotation turn FINE Even if lever is tilted to the point where the lever operating effort becomes heavy the inside track of turning machine continues rotating When the lever is tilted further to the stroke end the inside track stops rotating and the machine starts making pivot turn AA Standard screen MM Mode Select screen 1 Gear shift mode selector swit...

Page 265: ...y operations high productivity desired Sand soft soil Light duty operations easily slips Uneven ground soft rock Load changes easily Pushing up Uphill Pushing down Downhill Grading leveling Light duty operations Ripping Uneven ground soft rock Shoes slip easily Removing stumps side cutting MACHINE OPERATIONS AND CONTROLS OPERATION 3 214 ...

Page 266: ...or final drive and lower durability If there is no way to avoid operating the machine at high speed for a long time stop the machine every one hour for 30 minutes and let the track rollers and final drive cool off before starting up the machine again PRECAUTIONS WHEN TRAVELING DOWNHILL USE ENGINE BRAKE When driving downhill move the joystick steering directional and gear shift lever into low speed...

Page 267: ...s level or abnormality in urea SCR system may be detected If DEF level caution lamp or DEF system caution lamp lights up in red move the machine to a level place immediately and add DEF Pay attention to stopping of engine on slopes If the engine stops while working or traveling on a slope immediately depress the decelerator brake pedal to stop the machine completely DO NOT OPEN DOOR WHILE OPERATIN...

Page 268: ... toward bottom When dozing toward one side only operate with angled blade LEVELING WORK NOTICE Avoid leveling work on rocky or stony ground It can damage the blade To finish the ground to a flat surface after digging or piling soil put a full load of soil on the front face of the blade and operate the blade up and down in small movements while traveling for ward Finally float the blade travel at l...

Page 269: ...trees with a diameter of 10 to 30 cm 3 9 to 11 8 in raise the blade high and push a few times to fell the tree Next travel in reverse and dig the corner of the blade into the ground to cut and dig up the roots When doing this never hit the tree at high speed or apply shock to fell the tree SIDE CUTTING OPERATION In side cutting operation with unbalanced load on the blade use the counter rotation t...

Page 270: ...A is 55 and distance B be tween the joints is 470 mm 18 5 in This is suitable for general operations Maximum blade edge angle A is 58 and distance B be tween the joints is 516 mm 20 3 in This is suitable for digging operations on clay soil or hard soil This will improve the removal of the soil from the blade and re duce spillage of soil over the back of the blade This is suitable also for dozing o...

Page 271: ... Shorten than the standard length Decreas es Set grease fitting 4 to the position of V shape groove 6 on the cover 3 Be sure to set so since shortening more can cause damage Set to standard length Becomes standard Set grease fitting 4 to the position of V shape groove 7 on the cover 3 4 After adjustment check that top faces of rods 8 and 9 are not twisted each other 5 Install cover 3 6 Install bol...

Page 272: ...hine is digging do not stay there but move back to a level place then start digging again If the idler or sprocket floats because of a hard obstacle during dozing or ripping work avoid that obstacle since it is difficult to move it METHOD FOR CHECKING AND ADJUSTING Adjust the track tension to a proper level Check the tension by measuring clearance A between the idler and carrier roller shown in th...

Page 273: ...EIGHT Eliminate the sag of the track and measure at the center of the track Standard dimension h 57 5 mm 2 3 in Repairable limit 16 5 mm 0 6 in METHOD FOR MEASURING TRACK ROLLER DIAMETER 1 Measure the link tread dimension C as shown in the fig ure 2 Stop the machine at a position where the link tread at which dimension C was measured is perfectly in contact with the roller tread 3 Measure dimensio...

Page 274: ... is touched by accident the work equipment may move suddenly causing a seri ous accident Before leaving the operator s seat al ways set parking brake lever 3 and work equipment lock lever 5 securely in LOCK position 1 Depress decelerator brake pedal 1 2 Set joystick steering directional and gear shift lever 2 to N NEUTRAL position Position A FORWARD Position B REVERSE To keep the machine stopped f...

Page 275: ...round check for oil or coolant leakage and for abnormality in work equipment exterior parts and undercarriage If oil or coolant leakage or any abnormality is detected repair it 2 Check DEF tank pump injector hose and joint for leakage If any abnormality is found ask your Komatsu distributor for repair 3 Fill the fuel tank 4 Check the engine compartment for paper and debris Clean out any paper and ...

Page 276: ...draulic tank inspection cover 3 DEF tank filler port cover 4 Fuel tank inspection cover 5 Radiator filler port inspection cover 6 Hydraulic tank oil filler cap 7 Places locked with special key Fuel tank fuel filler cap 8 REMARK If padlock A is to be used it is recommended to use the type that has the cover to protect the key hole OPERATION MACHINE OPERATIONS AND CONTROLS 3 225 ...

Page 277: ... L LOCK F OPEN position A Working angle of key 180 B 45 2 Turn the key counterclockwise 3 Align the rotor groove with match mark 2 of the cap 4 Turn the cap slowly If a click is heard the cap is unlocked and can be re moved PROCEDURE FOR CLOSING CAP WITH LOCK 1 Screw in the cap until it becomes tight then insert the key into the key slot 2 Turn the starting switch key to LOCK position then remove ...

Page 278: ...wise approxi mately 35 The cap stops at the stopper and you can open it PROCEDURES FOR CLOSING FUEL FILLER PORT CAP 1 After turning lever 1 in the c direction counterclock wise keep it in that position and fit the cap 2 Turn lever 1 in the d direction clockwise until it stops at the stopper and then tilt it in the b direction OPERATION MACHINE OPERATIONS AND CONTROLS 3 227 ...

Page 279: ...ver by pulling the cover handle Cab door opener Position A OPEN Position B CLOSE LOCK Cover other than cab door opener Position A OPEN Position B CLOSE LOCK METHOD FOR LOCKING COVER WITH LOCK 1 Close the cover and insert the key into the key slot 2 Turn the starting switch key to CLOSE position B then remove the key MACHINE OPERATIONS AND CONTROLS OPERATION 3 228 ...

Page 280: ...ay move down by its own weight METHOD FOR OPENING DEF TANK FILLER PORT COVER 1 Insert the key into key slot 1 2 Turn the key counterclockwise and remove it Position A OPEN Position B CLOSE LOCK 3 Press button 2 Knob 3 rises and lock is released 4 Pull handle 4 and open DEF tank filler port cover METHOD FOR LOCKING DEF TANK FILLER PORT COVER 1 Close the DEF tank filler port cover 2 Lower knob 3 to ...

Page 281: ... for a long time with the grille at vent of the front window defroster open water drops stick to the outside surface of the glass and visibility gets worse In this case close the grille or change its direction If the cold air form the air conditioner blows directly against the machine monitor water may condense on the machine monitor screen In that case change the angle of the vent EXPLANATION OF ...

Page 282: ...nt dust from enter ing Use this method at dusty jobsite or when you want to prevent the entry of dust into the cab 1 Close the windows and doors 2 Set the blower selector switch to any position of 1 to 4 Set the air conditioner mode selector switch and tempera ture control switch to your desired position METHOD FOR CHECKING DURING OFF SEASON Even during the off season operate the air conditioner f...

Page 283: ...imit is over the refrigerant circuit gets clogged and may cause the failure of compressor Replace it every 2 years REMARK The exchange interval may be shortened depending on the usage condition of receiver Ask your Komatsu distributor for replacement of the receiver HANDLE AIR CONDITIONER OPERATION 3 232 ...

Page 284: ...wer button to supply the power to the radio and the frequency is shown on display As long as AUX is selected display indicates AUX on it Press the button again to turn the power off BAND AUX SELECTOR BUTTON Press band AUX selector button to select the desired band or AUX Each time the button is pressed the band changes FM AM AUX FM VOLUME CONTROL BUTTON Use the volume control button to control the...

Page 285: ...is button is pressed BAL Balance TRE Treble and BAS Bass will be selected in this order If this button is pressed while BAS is displayed the sound adjustment will be canceled DISPLAY A Band name AUX frequency clock and other character numeric information are displayed B Frequencies are displayed at steps of 50 kHz in certain areas C Lights up when a stereo broadcasting is heard while a FM station ...

Page 286: ...noise may occur The noise may occur if you pull out the input plug when AUX is selected or if you push in or pull out the plugs of the equipment to connect You can hear the sound through the speaker of the machine when you connect a commercially available porta ble audio equipment to the machine 1 Open cap a 2 Connect a portable audio equipment by using an commer cially available audio cable 3 Pre...

Page 287: ...an auto seek When a proper frequency is picked up the tuning automatically stops METHOD FOR ADJUSTING FREQUENCY AUTO PRESETTING 1 Press band AUX selector button 1 and select FM or AM 2 Hold down sound control button 2 When a proper frequency is picked up it is automatically registered to preset memories 1 to 6 METHOD FOR CALLING PRESET 1 Press band AUX selector button 1 and select FM or AM 2 Press...

Page 288: ...n the dis play You can adjust the sound balance 2 Press tuning time adjustment button 2 to adjust the sound balance Press the button and the speaker output on the R side increases by 1 R1 to R7 Press the button and the speaker output on the L side increases by 1 L1 to L7 METHOD FOR ADJUSTING HIGH REGISTER RANGE TREBLE 1 Press sound control button 1 to light up TRE on the dis play You can adjust th...

Page 289: ...he HOUR display portion You can adjust the hour 3 Press tuning time adjustment button 2 to adjust the hour If you press button HOUR display increases by 1 If you press button HOUR display decreases by 1 4 Press display selector button 1 to flash the MINUTE dis play portion You can adjust the minute 5 Press tuning time adjustment button 2 to adjust the minute If you press button MINUTE display incr...

Page 290: ...TIONS weight and dimensions vary depending on the kind of track shoes blade or other equipment REMOVE CAB Operator s seat and control levers are made in one unit with the cab If cab is removed machine cannot be op erated If you have any trouble in transportation consult your Komatsu distributor METHOD FOR REMOVING WORK EQUIPMENT Overall width can be shortened by angling the blade fully Re ferring ...

Page 291: ... center of gravity of the machine shifts suddenly at the joint between the ramps and the trailer and it is dangerous that the machine loses its balance Pass slowly When loading or unloading the machine be sure to use ramps or platform and follow the procedure shown be low PROCEDURES FOR LOADING MACHINE Load on a firm and level ground 1 Park a trailer on a firm and level ground Maintain a safe dist...

Page 292: ...ine onto a trailer secure the machine as follows 1 Lower the work equipment slowly When transporting with work equipment installed 2 Set the work equipment lock lever securely to LOCK posi tion L 3 Set the parking brake lever securely to LOCK position L 4 Stop the engine and remove the key from the starting switch 5 Securely lock the glass window cab door engine side cov er hydraulic tank inspecti...

Page 293: ...ocks 1 to the tires to secure the trailer 4 Install ramps 2 Set gap 3 between ramps 2 to match the distance be tween the right and left tracks and keep angle 4 to a maximum of 15 If ramps 2 bend appreciably under the weight of the ma chine put wooden block 5 under the ramps to support them 5 Remove the chains and wire ropes fastening the machine 6 Start the engine 7 When transporting the machine w...

Page 294: ...k lever and parking brake lever in LOCK position to prevent the machine or work equipment from moving unexpectedly Never enter the area under or around a lifted machine There is a danger that the machine loses its balance Use the procedure below to set the machine in the proper posture and use the lifting equipment when lifting the machine NOTICE This lifting method applies to the standard specifi...

Page 295: ...t the wire ropes will not be broken at sharp edges or narrow places When using a spreader beam select an ample width to prevent contact with the machine 6 Just before slinging the machine lift it off the ground by 100 to 200 mm 3 9 to 7 9 in while it is being set 7 Check that the wire ropes are free of looseness and the machine is kept on a level state 8 Sling the machine slowly TRANSPORTATION OPE...

Page 296: ...tor or request a qualified company to perform the operation Coolant is toxic so never pour it into drainage ditches or drain it onto the ground surface NOTICE Komatsu recommends the use of Non Amine Engine Coolant AF NAC as coolant Non Amine Engine Coolant AF NAC is already diluted with distilled water so it is not flammable For the concentration of Non Amine Engine Coolant AF NAC see METHOD FOR U...

Page 297: ...rop Maintain the battery charging rate as close as possible to 100 Insulate it against cold temperature to ensure that the machine can be start ed easily in the next morning REMARK Measure the gravity of the electrolyte and calculate the charging rate from the following conversion table Electrolyte Temperature Charging Rate 20 C 68 F 0 C 32 F 10 C 14 F 20 C 4 F 100 1 28 1 29 1 30 1 31 90 1 26 1 27...

Page 298: ... to break the devices in the tank when it freezes If DEF tank level is lower than the defined level for the cold weather DEF may freeze easily to damage the parts in DEF system If the filler cap freezes defreeze and open After operation in water or mud remove water from undercarriage as described below to extend undercar riage service life Do not leave the machine running idle for a long time The ...

Page 299: ...nect switch key to OFF position and pull it out and keep it with covered condition Place all control levers in NEUTRAL position place the work equipment lock lever and parking brake lever in LOCK position and set the fuel control dial to Low idle MIN position To prevent rust fill the cooling circuit with Non Amine Engine Coolant AF NAC to give a density of at least 30 for the engine coolant MAINTE...

Page 300: ...n this case set the information again For detail see CLOCK ADJUSTMENT and HANDLE RADIO When starting the engine perform the engine warm up operation thoroughly If the machine has been stored for more than 2 months perform the following procedure Before starting the engine replace DEF filter and fill up DEF tank according to the procedure in METHOD FOR REPLACING DEF FILTER Start the engine and chec...

Page 301: ...hine and the towed machine Move the machine slowly Do not apply a sudden load to the wire rope NOTICE The maximum towing capacity for this machine is 127600 N 13010 kg Do not tow any load greater than this For details of the method of towing contact your Komatsu distributor If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic sys tem the brake w...

Page 302: ...ll at tack your clothes and skin If it gets on your clothes or on your skin immediately wash it off with a large amount of clean water If it gets in your eyes wash the eyes immediately with clean water then consult a doctor for medical treat ment When handling batteries always wear protective eye glasses and rubber gloves When removing the battery first disconnect the cable from the ground normall...

Page 303: ... 6 After replacing the battery secure it with the battery mounting fixtures according to the following procedure 4 places 1 Tighten nuts A evenly into the right and left rods by hand 2 Tighten nuts A Tightening torque 1 96 to 2 94 Nm 0 2 to 0 3 kgm 1 45 to 2 17 lbft 3 Tighten nuts B by hand until they touch the face of nuts A 4 Hold nuts A with a wrench and tighten nuts B Tightening torque 11 8 to...

Page 304: ... Set the charging current to 1 10 of the value of the rat ed battery capacity when performing rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or the battery cells will dry up and this may cause the battery to catch fire and explode If the battery electrolyte is frozen do not charge the battery or start the engine with a dif...

Page 305: ...to bring the clips in contact with each other or with the machine NOTICE The starting system for this machine uses 24 V Accordingly the normal machine must be equipped with a 24 V power supply The sizes of the jumper cables and clips should be suitable for the battery size The battery of the normal machine must be the same capacity as that of the failed machine Check the cables and clips for damag...

Page 306: ...K position 2 Check both of normal machine and failed machine that the control levers are in NEUTRAL position 3 Make sure the clips are firmly connected to the battery terminals 4 Start the engine of the normal machine and run it at high idle Max speed 5 Turn the starting switch of the failed machine to START position and start the engine If the engine does not start at first try again after 2 minu...

Page 307: ...osition Defective wiring Check repair Insufficient battery charge Charge the battery Battery disconnect switch is at OFF position Turn it to ON position Engine shutdown secondary switch is at ENGINE STOP position Set it NORMAL position Incorrect adjustment of safety switch Adjust safety switch Pinion of starting motor repeats en gaging and disengaging rattles Insufficient battery charge Charge the...

Page 308: ...electrical intake air heater Replace Malfunction of heater relay Check repair heater relay Malfunction of air conditioner Blown fuse Check repair Insufficient battery charge Charge the battery Defective air conditioner switch Replace air conditioner switch Defective blower switch Replace blower switch Defective compressor Replace Engine does not start L04 lights up on monitor Damaged data in the c...

Page 309: ...e WHEN RE QUIRED Add oil to the specified level Lack of traction force Travel speed is low Lack of engine power See PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS Acceleration of travel speed is low Hydraulic oil temperature is low Warm up Even if the joystick steering direc tional and gear shift lever is operat ed machine does not move off Parking lever is in LOCK position Set to FREE Charge pump...

Page 310: ...gh Lighten the work load to prevent trav el relief Work equipment is relieved Avoid operating the blade to the stroke end of cylinder Continuous high speed travel Drive in lower speed range Clogged oil cooler fins or damaged fin Clean or repair See WHEN RE QUIRED OPERATION TROUBLES AND ACTIONS 3 259 ...

Page 311: ...ng system See WHEN REQUIRED Clogged radiator fins or damaged fin Clean or repair See WHEN RE QUIRED Defective thermostat Replace thermostat Loosened radiator filler cap in high altitude operation Tighten cap or replace packing Defective monitor Replace monitor Engine coolant temperature caution lamp lights up Lowered coolant level leakage of coolant Check add coolant repair See CHECKS BEFORE START...

Page 312: ...arm buzzer sounds Contact your Komatsu distributor Engine suddenly loses power Entered derate mode Contact your Komatsu distributor IF MACHINE MONITOR SHOWS WARNING DISPLAY When the action level display 1 or caution lamp 2 is shown on the display of the machine monitor press switch F5 to dis play the Current Abnormality screen and check the details and remedy Take the actions according to the mess...

Page 313: ......

Page 314: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1 ...

Page 315: ...remove the strainer while adding DEF PRECAUTIONS FOR WELDING When performing welding turn the starting switch to OFF position check that the system operating lamp is not lit Turn the battery disconnect switch to OFF position and remove the key Do not apply a voltage higher than 200 V continuously Connect grounding cable within 1 m 3 ft 3 in of the area to be welded If grounding cable is connected ...

Page 316: ... to get your fingers caught between the tank etc when opening or closing the radiator grille Check that the lock is securely set when opening the radiator grille Check that there is no abnormality in the lock or link portion as well When opening the radiator grille be careful not to hit your head etc against it Check the hoses and piping which move together with the radiator grille for cracks and ...

Page 317: ...e machine and get caught in the lever linkage mechanism Are there any leakage of coolant or oil Have all nuts and bolts been tightened Checks while the engine is running To perform inspection while the engine is running one worker must always sit on the operator s seat and be ready to stop the engine at any time All workers must maintain contact with the other workers Increase the engine speed to ...

Page 318: ...il at the specified interval Oil corresponds to blood in the human body always be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of failures 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 Never mix oils of different grades or brands Always ad...

Page 319: ...tion in performance The ASTM diesel fuel recommended by Komatsu may contain 5 or less of biofuel The EN diesel fuel may contain 7 or less of it Use the fuel which is filled into the storage tank or the fuel tank of the machine as soon as possible When the diesel fuel is changed to the one mixed with the bio fuel replace the fuel prefilter cartridge and the fuel main filter cartridge with new ones ...

Page 320: ...t washed and cleaned it can cause corrosion to the contaminated area and emit toxic gas When disposing of DEF treat it as an industrial waste The container for DEF is an industrial waste as well It should be treated in the same way Never use an iron or aluminum container when disposing DEF because toxic gas may develop and a chemical reaction may corrode the container Use a container made of resin...

Page 321: ...tively Coupled Plasma analyzer is used for measuring the concentration of iron copper and other metal powder in the oil Measurement of quantity of iron particles A PQI Particle Quantifier Index measuring instrument is used for measuring the quantity of iron particles of 5 μm or more en abling early detection of failures Others Measurements are made of items such as the ratio of water coolant and f...

Page 322: ...lationship between the upper limit of storage temperature and the storage period of DEF is shown in the table Temperature of storage area Storage period Max 10 C 50 F Up to 36 months Max 25 C 77 F Up to 18 months Max 30 C 86 F Up to 12 months Max 35 C 95 F Up to 6 months Do not store DEF in the temperature of 35 C 95 F or above FILTER Filters are extremely important safety parts They prevent impur...

Page 323: ... supply connector Do not connect the optional power supply to the fuse or starting switch or battery relay etc HANDLE HYDRAULIC COMPONENTS The hydraulic system is at high temperature during and just after operation In addition high pressure is applied to the hydraulic system thus pay attention to the following matters when performing inspection and maintenance of it Lower the work equipment to the...

Page 324: ...m kgm lbft 6 8 10 12 14 10 13 17 19 22 13 3 31 67 111 172 1 35 3 2 6 8 11 3 17 5 9 8 22 8 48 8 81 4 127 11 8 to 14 7 27 to 34 59 to 74 98 to 123 153 to 190 1 2 to 1 5 2 8 to 3 5 6 to 7 5 10 to 12 5 15 5 to 19 5 8 7 to 10 8 20 3 to 25 3 43 4 to 54 2 72 3 to 90 4 112 to 141 16 18 20 22 24 24 27 30 32 36 260 360 510 688 883 26 5 37 52 3 70 3 90 192 268 378 508 651 235 to 285 320 to 400 455 to 565 610...

Page 325: ...16 18UNF 19 44 4 5 32 5 35 to 54 3 5 to 5 5 25 3 to 39 8 11 16 16UN 22 74 7 5 54 2 54 to 93 5 5 to 9 5 39 8 to 68 7 13 16 16UN 27 103 10 5 75 9 84 to 132 8 5 to 13 5 61 5 to 97 6 1 14UNS 32 157 16 0 115 7 128 to 186 13 0 to 19 0 94 0 to 137 4 1 3 16 12UN 36 216 22 0 159 1 177 to 245 18 0 to 25 0 130 2 to 180 8 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE 4 12 ...

Page 326: ...MAINTENANCE AIR CONDITIONER 4 38 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 4 39 METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT 4 40 METHOD FOR CHECKING ELECTRICAL INTAKE AIR HEATER 4 40 METHOD FOR ADJUSTING SHIMS AT CENTER BALL 4 41 CHECKS BEFORE STARTING 4 42 EVERY 50 HOURS MAINTENANCE 4 43 METHOD FOR LUBRICATING 4 43 METHOD FOR LUBRICATING EQUALIZER BAR CENTER PIN 4 44 EVERY 250 HOURS M...

Page 327: ...VAL WHEN DIESEL FUEL MIXED WITH BIO FUEL IS USED If the diesel fuel which does not include the bio fuel is changed to the diesel fuel mixed with bio fuel set the maintenance interval as follows Replace the fuel prefilter cartridge When the machine is operated first 250 hours after the diesel fuel has been changed to the diesel fuel mixed with bio fuel and when the machine is operated further 250 h...

Page 328: ... where the foothold is poor be careful not to fall because of the re action when pulling out the element METHOD OF CHECKING NOTICE Do not clean the element before the air cleaner clogging caution lamp lights up or the yellow piston of the dust indicator laps over the peripheral red zone If the element is cleaned before the above the air cleaner cannot display its normal performance and the cleanin...

Page 329: ...it under direct sunlight Never remove inner element 5 If it is removed dirt will enter and can cause an engine trouble Do not use a screwdriver or other tool 3 Hold the outer element 4 rock it lightly up and down and to the right and left and pull it out while turning it to the right or left 4 Cover the air connector at the bottom of the air cleaner body with a clean cloth or tapes to prevent entr...

Page 330: ...reuse the inner element When replacing the outer element replace the inner element with new one at the same time If the outer element and cover are installed while the inner element is not installed properly the outer element may be damaged The sealing portion of the improper part lacks precision and allows the entry of dust which leads to damage of the engine Do not use such improper part 11 Chec...

Page 331: ...e an engine trouble Do not use a screwdriver or other tool 3 Hold the outer element 4 rock it lightly up and down and to the right and left and pull it out while turning it to the right or left 4 Clean the interior of the air cleaner body cover 3 and vacuator valve 6 with a clean cloth a whisk or others NOTICE If the outer element and cover are installed while the inner element is not installed pr...

Page 332: ...e position between 3 7 to 5 0 kPa 0 04 to 0 05 kg cm2 0 57 to 0 71 PSI but this does not indicate any ab normality For the machines installed with a pre cleaner of large intake resistance or a rain cap immediately after a new element has been installed the yellow piston of the dust indicator may go to the position between 5 0 to 6 2 kPa 0 05 to 0 06 kg cm2 0 71 to 0 85 PSI but this does not indica...

Page 333: ...may cause serious problems such as corrosion of the engine and aluminum parts of the cooling system To maintain the anti corrosion properties of Non Amine Engine Coolant AF NAC always keep the density of Non Amine Engine Coolant between 30 and 64 Non Amine Engine Coolant AF NAC is already diluted with distilled water When using coolant investigate the lowest temperature in the past and decide the ...

Page 334: ...ion cover under the engine on the lower part of the machine 7 Open drain valve 3 to drain the coolant REMARK Keep air bleeding valve 4 open while adding the coolant or water to the cooling system The air which is collected during adding of the coolant or water will be bled After adding the coolant or water close air bleeding valve 4 8 After draining the coolant close drain valve 3 and add city wat...

Page 335: ... minutes and then run at full speed for a further 5 minutes At this time keep the radiator cap removed The air is bled from the coolant 17 Open the hydraulic tank inspection cover and drain the coolant from reservoir tank 5 18 Clean the inside of reservoir tank 5 19 Add Non Amine Engine Coolant AF NAC to the middle between FULL and LOW 20 Stop the engine 21 Tighten radiator cap 1 22 Check the cool...

Page 336: ...nd dusts from inside of the machine 3 After cleaning install covers 1 to 4 with the mounting bolts to the bottom of the machine METHOD FOR CHECKING AND CLEANING RADIATOR FRONT k k WARNING If compressed air high pressure water or steam hits your body directly or dirt is scattered by the com pressed air high pressure water or steam there is a danger of personal injury Always wear protective equipmen...

Page 337: ...track tension is not in the standard range adjust it METHOD FOR ADJUSTING k k WARNING Never loosen plug 1 more than 1 turn If plug 1 is loosened more than 1 turn there is a danger of plug 1 flying out under the high internal pressure of the grease Never loosen any part other than plug 1 Never put your face in the mounting direction of plug 1 If the track tension cannot be loosened by the above pro...

Page 338: ...he following procedure If track tension is not relieved by this procedure contact your Komatsu distributor for repairs NOTICE The safety indicator is stuck to the back of cover 3 Take care not to damage the safety indicator When removing cover 3 be careful not to let any dirt or soil get in 1 Remove cover 3 2 Loosen plug 1 gradually to release the grease When loosening plug 1 turn it a maximum of ...

Page 339: ...ig ure Tightening torque of shoe bolt 490 49 Nm 50 5 kgm 362 36 2 lbft 2 Check that the nut and track shoe are in close contact with the link contact surface 3 After checking retighten by 120 10 METHOD FOR RETIGHTENING MASTER LINK CONNECTING BOLT 1 Tighten the master link connecting bolts in the order shown in the figure Tightening torque for master link connecting bolt 343 39 Nm 35 4 kgm 253 29 l...

Page 340: ...RANCE Since the idlers are forced to move forward and backward by an external force guide plates will be worn out Wear of guide plates will cause the vibration of idlers from side to side or inclination of the idlers and running off of track links from the idlers or unevenly worn idler and links may result Check and adjust it as follows 1 Drive the machine by 1 to 2 m 3 ft 3 in to 6 ft 7 in on a f...

Page 341: ... limit a Height of end bit 204 8 187 7 4 b Width of end bit 325 12 8 300 11 8 c Height of cutting edge Center of bolt mounting hole to edge 102 4 85 3 3 REMARK If both sides of the cutting edge are worn out replace with new ones If the wear extends to the mounting surface repair the mounting surface before installing the cutting edge 5 Loosen nut 1 and remove bolt 2 6 Remove the cutting edge and e...

Page 342: ...e fan rotates in reverse take extreme care of scattering of dust When stopping the engine during the Fan Reverse Mode first run the engine at low idle then stop it The dust and dirt stuck to the radiator and cooler can be blown out by rotating the hydraulic drive fan in the reverse direction 1 Turn starting switch 1 to OFF position and stop the en gine 2 Set parking brake lever 2 and work equipmen...

Page 343: ...m the operator that the direction of rotation of the fan has not been changed Stop the engine once and perform the steps 3 to 8 10 Turn the starting switch 1 to START position and start the engine The hydraulic fan rotates in reverse 11 Turn the fuel control dial at High idle MAX position and run the engine at high idle Change the time for running the engine at high idle corresponding to the serio...

Page 344: ... Fan Reverse Mode within less than 5 minutes If the fan reverse rotation is performed for a long time the DEF hose may freeze 14 Close engine side cover 6 hydraulic tank inspection cover 10 and fuel tank inspection cover 11 15 Install front cover 7 and engine side covers 8 and 9 with mounting bolts 16 Install undercovers 4 and 5 with the mounting bolts MAINTENANCE MAINTENANCE PROCEDURE 4 31 ...

Page 345: ...radiator grille to the fully opened position check that it is locked and then release your hand 3 Remove mud dirt leaves etc in the radiator fins Blow off the heavy clogging with the compressed air Steam or water may be used instead of compressed air 4 Check the rubber hoses If any hose is cracked or be comes brittle replace it with a new one Also check all the hose clamps for looseness 5 Close th...

Page 346: ... nut tighten nut 2 by hand until it is seated Then tighten it 15 to 30 by using a tool METHOD FOR CLEANING FUEL TANK BREATHER At the check and maintenance if the breather is dirty clean it 1 Remove nut 2 of breather assembly 1 on the top of the fuel tank Use a tool when the nuts are so tight to remove 2 Remove cover 3 3 Remove dirt sticking to breather element 4 4 Clean in clean diesel fuel or flu...

Page 347: ...pply spray lubricant through the bushing slit of the hinge 2 If the bushing is worn replace the hinge METHOD FOR CHECKING DOOR LATCH 1 Keep the door open 2 Check if the grease in the latch dried out If the amount of grease is low or there is no more grease coat the inside of the latch with grease from portion 1 REMARK If there is no more grease inside the latch the movement of the door will become...

Page 348: ...dow washer fluid for automobile through the filler port Be careful not to let dirt or dust get in when adding fluid Mixture ratio of pure washer fluid and water The proper mixing proportion varies with the ambient temperature Add washer fluid diluted with water at the following proportion Area season Mixing proportion Freezing temperature Normal Washer fluid 1 3 water 2 3 10 C 14 F Winter in cold ...

Page 349: ...ng removed from the arm Otherwise it may hit the glass and the glass may be broken If the glass has rubber abrasion of the wiper blade remove it with a plastic scraper or by using a cloth etc with a neutral detergent Do not use any solvent to remove it because it has a bad influence upon the wiper blade rubber METHOD FOR REPLACING WIPER BLADE If the blade is damaged it will not wipe the window cle...

Page 350: ...on of the arrow The blade comes off 2 Install the new blade and hook it securely METHOD FOR REPLACING DOOR WIPER The front wiper is hooked at portion A 1 Move the blade in the direction of the arrow The blade comes off 2 Install the new blade and hook it securely MAINTENANCE MAINTENANCE PROCEDURE 4 37 ...

Page 351: ...erant gas Hydrofluorocarbons HFC 134a condition with the sight glass inspection window of the receiv er while the air conditioner is in operation A Blue The air conditioner is operated normally B Pink The receiver drier needs to be replaced If the sight glass inspection window is pink contact your Ko matsu distributor for repair REMARK The bubbles or condensation may be generated in the sight glas...

Page 352: ...t high speed immediately after startup or a cylinder is pushed up to its stroke end air taken inside the cylinder may cause the piston pack ing to be damaged 1 Start the engine 2 Run the engine at low idle Run the engine at low idle for 10 minutes after start ing and then start the following work 3 Move each cylinder of the work equipment to approxi mately 100 mm 3 9 in before the stroke end and r...

Page 353: ...ICE Finish the steps of operating the blade control lever fully forward and backward and to the right and left within 15 seconds after the engine has stopped 1 Stop the machine Place the machine on a firm level ground 2 Lower the work equipment to the ground and stop the engine 3 Turn the starting switch to ON position 4 Set the work equipment lock lever to FREE position 5 Operate the blade contro...

Page 354: ...follows Correct value for play at ball joint 0 2 to 0 7 mm 0 008 to 0 047 in Standard shim thickness 6 to 8 mm 0 236 to 0 315 in 1 Remove bolt 1 and loosen bolt 2 2 Remove excess shims 3 1 to 2 pieces and tighten bolts 1 and 2 lightly 3 Angle and tilt the blade to check the play at center ball por tion When no creak sound is heard and the blade moves smoothly the adjustment is completed If a creak...

Page 355: ...ing coolant level adding coolant Method for checking oil level in engine oil pan adding oil Method for checking dust indicator Method for checking electric wiring Method for checking fuel level adding fuel Method for checking DEF level adding DEF Method for checking lamps operation Method for checking machine monitor Method for removing deposit in engine compartment Method for checking horn operat...

Page 356: ...a grease pump pump in grease through the grease fittings 3 After greasing wipe off any old grease that is pushed out 1 U frame mounting pin 1 place each of right and left 2 Angle cylinder bottom pin 1 place each of right and left 3 Center trunnion ball 1 place 4 Pitch rod pin 2 places 5 Turnbuckle screw 2 places 6 Lift cylinder bottom pin 1 place each of right and left 7 Lift cylinder head pin 1 p...

Page 357: ...wn by arrow 2 By using a grease pump pump in grease through the grease fittings REMARK Lower the blade until the idler is raised 1 to 2 cm 0 4 to 0 8 in from the ground and perform lubrication The grease will fill the whole circumference of the pin MAINTENANCE PROCEDURE MAINTENANCE 4 44 ...

Page 358: ...Tilt cylinder head pin 1 place METHOD FOR LUBRICATING EQUALIZER BAR SIDE PIN 1 place each on right and left sides 1 Remove all soil and sand from the top of the track frame and top of the cover 2 Clean the grease fitting shown by arrow 3 Supply grease by using 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 d...

Page 359: ...RY ELECTROLYTE LEVEL k k WARNING Do not use the battery if the battery electrolyte level is below LOWER LEVEL line If you do so it will reduce the service life of the battery In addition it may cause an explosion Since the battery produces combustible gas it can explode Do not bring any open flame close Battery electrolyte is dangerous object Also take care that it does not stick your eye or skin ...

Page 360: ...en the electrolyte level is below the center line be tween UPPER LEVEL U L line and LOWER LEVEL L L line The battery electrolyte level is low Add purified water according to the following procedure 1 Remove the plastic sheet 1 installed above the bat tery 2 Remove cap 2 immediately and add purified water example commercially available battery liquid up to UPPER LEVEL U L line 3 After adding the pu...

Page 361: ...B Low Electrolyte level is not up to bottom of sleeve so poles appear straight and not bent If the electrolyte does not reach sleeve 4 always add the purified water such as a commercial battery fluid so that the level reaches the bottom of sleeve 4 UPPER LEV EL 5 After checking adding the purified water tighten cap 2 securely REMARK If the purified water is added to above the bottom of sleeve 4 us...

Page 362: ... lock lever 1 in FREE position F 4 Set parking brake lever 3 to FREE position F 5 Depress decelerator rake pedal 4 and set joystick steer ing directional and gear shift lever 5 to the forward 6 Operate fuel control dial 6 and gradually raise the engine speed to full throttle 7 Check that the machine can move or that the warning screen is displayed on the machine monitor When the machine cannot mov...

Page 363: ...t wrench and a filter wrench Prepare a container to catch drained oil 1 Remove cover 1 under the front cover and pull out the drain hose 2 Place the oil container to catch oil under the hose 3 Loosen drain plug P to drain oil Do it slowly so that you do not get splashed with drained oil 4 Tighten drain plug P 5 Check the drained oil If there are excessive metal particles or foreign material contac...

Page 364: ...ller port F until the oil level is be tween H and L marks on dipstick G 14 Run the engine at low idle for a while and then stop it 15 Check that the oil level is between H and L marks on the dipstick When the oil level is below the mark L The oil is insufficient Add oil through the oil filler port F REMARK When the ambient temperature is low water or emulsified matter may stick to the dipstick oil...

Page 365: ...maintenance of the fuel system pay more attention than normal to the entry of dirt If dirt sticks to any part use fuel to wash it off completely Prepare a filter wrench and a container to catch the fuel 1 Open the inspection cover under the fuel tank on the right side of the machine 2 Turn fuel supply valve 1 to CLOSE position C 3 Open the engine side cover on the left side of the ma chine 4 Take ...

Page 366: ...t to let dirt or dust get into the center portion on the clean side 14 After the packing surface reaches the sealing surface of the filter head tighten the filter cartridge 3 4 turns REMARK If the filter cartridge is fastened too much the packing will be damaged and this leads to leakage of fuel If the filter cartridge is too loose fuel will also leak from the packing Be sure to observe the tight ...

Page 367: ...t the engine 21 Check the filter seal surface and the mounting face of the transparent cup for fuel leakage If there is any leakage of fuel check the tightening condi tion of the filter cartridge If the fuel still leaks remove the filter cartridge again and check the packing surface for damage or foreign material If the packing surface is damaged or there is any foreign material on it replace the ...

Page 368: ...tor s seat and re move recirculation air filter 2 2 Install the new recirculation air filter 2 and tighten knob 1 When fixing it with knob check the filter position by touch ing it with hands or looking at it and then tighten it METHOD FOR REPLACING FRESH AIR FILTER 1 Open the hydraulic tank inspection cover on the left side of the machine and check the position of step 1 Use step 1 to remove or i...

Page 369: ...r at the rear of the machine and remove the fresh air filter 3 Install the new fresh air filter and tighten knob 2 REMARK When the inside of the filter case is dirty clean it before in stalling the filter MAINTENANCE PROCEDURE MAINTENANCE 4 56 ...

Page 370: ...acity each of right and left 8 1 ℓ 2 14 U S Gal Prepare a handle and a container to catch the drained oil 1 Stop the machine so that the TOP mark comes on the top while a line between TOP mark and plug P becomes per pendicular to the ground surface 2 Place the oil container to catch oil under plug P 3 Remove plugs P and F by using the handle and drain oil 4 Check O rings attached to plugs P and F ...

Page 371: ...parts than those in the conventional injection pump and nozzles If any cartridge other than a Komatsu genu ine filter cartridge is used dust or dirt may get in and cause problems with the injection system Never use a substitute When performing the inspection or maintenance of the fuel system pay more attention than normal to the entry of dirt If dirt sticks to any part use fuel to wash it off comp...

Page 372: ...It is not necessary to remove the plugs at the fuel prefilter head and at the fuel main filter head When the engine runs out of fuel use the same procedure to operate feed pump 4 and bleed the air 3 After bleeding air push in the knob of feed pump 4 and tighten it 11 Turn the starting switch key to START position C and start the engine 12 Check the filter seal surface and the mounting face of the ...

Page 373: ...ith a new one 4 Install cover 3 and nut 2 In order not to damage the threaded portion of nut tighten nut 2 by hand until it is seated Then tighten it 15 to 30 by using a tool METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner turbocharger aftercooler engine MAINTENANCE PROCEDURE MAINT...

Page 374: ...lic tank Use a tool when the nuts are so tight to remove 2 Remove cover 3 3 Replace breather element 4 with a new one 4 Install cover 3 and nut 2 In order not to damage the threaded portion of nut tighten nut 2 by hand until it is seated Then tighten it 15 to 30 by using a tool MAINTENANCE MAINTENANCE PROCEDURE 4 61 ...

Page 375: ...er element cannot be flushed Flushing or regenerating of it will degrade the performance of element and will cause the breakage of the DEF tank Never reuse the DEF element Always stop the engine and clean around the DEF tank before replacing After the engine is stopped the DEF system devices automatically purge the DEF in the DEF injec tor and DEF pump and return it to the DEF tank to prevent malf...

Page 376: ... assembly 1 4 Remove cover 3 5 Replace breather element 4 with a new one 6 Install cover 3 and nut 2 In order not to damage the threaded portion of nut tighten nut 2 by hand until it is seated Then tighten it 15 to 30 by using a tool 7 Install mounting bolts B and C MAINTENANCE MAINTENANCE PROCEDURE 4 63 ...

Page 377: ...istributor to replace it When vertical flaw 2 that crosses horizontal flaw 1 is found When part of the belt has tears 3 REMARK When only horizontal flaw 4 is found replacement is not re quired METHOD FOR CHECKING FOR LOOSE ROPS MOUNT BOLTS Check that the bolts for looseness or damage Rear bolts 1 2 pieces Located under the tray at the rear of the operator s seat Front bolts 2 2 pieces Located unde...

Page 378: ...emoved oil may spout out Turn the cap slowly to release the internal pressure then remove it carefully Refill capacity 101 ℓ 26 7 U S Gal Prepare an oil container to catch oil a filter wrench and hose 1 Lower the work equipment to the ground and stop the engine 2 Loosen the cap of oil filler port F slowly on the top of the hydraulic tank to release the internal pressure in the hy draulic tank 3 Re...

Page 379: ... Open the hydraulic tank inspection cover on the left side of the machine 12 Turn battery disconnect switch 3 to OFF position 13 Remove hose clamps 4 4 pieces 14 Remove step 5 15 Remove U bolts 6 16 Remove step mounting bracket 7 17 Remove grease pump 8 18 Remove grease pump bracket 9 19 Remove battery cover 10 MAINTENANCE PROCEDURE MAINTENANCE 4 66 ...

Page 380: ... fixtures 12 2 places 22 Remove batteries 13 2 pieces 23 Remove battery tray 14 24 Remove U bolts 15 25 Remove bolts 16 4 pieces of the suction flange 26 Lift up tube assembly 17 27 Remove screws 18 2 pieces of the suction flange MAINTENANCE MAINTENANCE PROCEDURE 4 67 ...

Page 381: ...6 valve 25 and spring 24 37 Install cover 23 with bolts 22 3 pieces 38 Turn HST oil filter cartridge 27 counterclockwise by using the filter wrench and remove it 39 Clean the filter head 40 Fill the new filter cartridge with clean oil coat the seal and thread of the new filter cartridge with oil or apply thin film of grease then install it to the filter head 41 After the packing surface touches th...

Page 382: ... perform drilling welding or flame cutting Do not hit or roll it or subject it to any impact When disposing of it the gas must be released Ask your Komatsu distributor to have this work per formed NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs ...

Page 383: ...comes sooner Check the nitrogen gas charge pressure as follows 1 Place the machine on a firm level ground 2 Set the parking brake lever to LOCK position L 3 Raise the work equipment blade to the upper limit NOTICE Perform the following procedure for lowering the blade to the ground within 15 seconds after stopping the engine When the engine is stopped the pressure inside the accumulator gradually ...

Page 384: ...of the accumulator has gone down Contact your Komatsu dis tributor Work equipment does not go down Stops while going down METHOD FOR CHECKING ALTERNATOR Ask your Komatsu distributor to have the alternator checked If the engine is started frequently have this inspection performed every 1000 hours METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and...

Page 385: ...ore do not start the engine without the filter element The filter element cannot be flushed Flushing or regenerating of the filter element will degrade per formance of the filter As a result the turbocharger and aftercooler become dirty and the perform ance lowers or the crankcase pressure increases Never reuse the filter element since it can cause an engine failure After the filter element is rep...

Page 386: ... inside of KCCV because of con densation of water vapor in the blowby gas However as far as the coolant level is normal it is not a problem 3 Remove used O ring 6 sticking to case 4 and install a new O ring contained in the service kit Apply engine oil to the new O ring 4 While matching marks 7 of the new element with mark 8 of the case insert the element firmly into the end of the body When inser...

Page 387: ...val Take extreme care so that those bases are matched with each other 6 Fit ring 3 to the threaded part of the body and tighten it with the hand firmly until it stops 7 By using the special wrench further tighten the ring 1 15 to 2 15 turns 1 to 2 ridges of the ring If the engine is operated with the ring tightened insufficient ly oil and blowby gas may leak 8 Check the KCCV hose for leakage crack...

Page 388: ... cause leakage of the DEF Replace the DEF filter in the cor rect procedure The DEF freezes at 11 C 12 2 F If it is frozen replacement of the filter becomes difficult Re place the filter when the temperature around the DEF pump is higher than 11 C 12 2 F and in the condition that the DEF is not frozen After the engine is stopped the DEF system devices automatically purge the DEF in the DEF injector...

Page 389: ...sert the filter removal tool to the end where you cannot thrust it in any further 6 Turn filter removal tool 3 in reverse and remove filter 6 Filter 6 is removed and you can take it out together with filter removal tool 3 If filter 6 cannot be removed from the DEF pump grip fil ter removal tool 3 pull it down then it will be removed 7 Slide filter 6 down and remove spacer 5 from filter re moval to...

Page 390: ...emoved spacer 5 to filter removal tool 3 and keep them 10 Insert a new filter and a new equalizing element into the bottom of the DEF pump and lightly tighten them with hand 11 Tighten filter cap 1 Tightening torque 20 to 25 Nm 2 0 to 2 5 kgm 14 5 to 18 1 lbft MAINTENANCE MAINTENANCE PROCEDURE 4 77 ...

Page 391: ...ressure circuit hose 3 Brake system Brake oil pressure hose 4 Work equipment hy draulic system Work equipment pump delivery hose Work equipment pump LS hose Hydraulic drive fan hose Intake fan External work equipment hose Blade lift hose Blade tilt hose Blade angle hose Ripper lift hose 5 Others PPC accumulator METHOD FOR CHECKING WATER PUMP Check around the water pump for water leakage If any abn...

Page 392: ...hen performing the work Do not disassemble Do not bring open flame close to it or do not dispose of it in fire Do not perform drilling welding or flame cutting Do not hit or roll it or subject it to any impact When disposing of it the gas must be released Ask your Komatsu distributor to have this work per formed NOTICE If the nitrogen gas charge pressure in accumulator 1 is low and operations are ...

Page 393: ...ays check that the proper high pressure piping clamps are correctly installed Check visually or with a finger to check that there is no hardening of the rubber portion and no loose bolts of the mounting clamps 5 places for the high pressure piping between the supply pump and the common rail If there is any loose bolt or hardened rubber portion ask your Komatsu distributor for replacement Replaceme...

Page 394: ...vent the fuel from coming into contact with high temperature parts of the engine and causing a fire if the fuel should leak or spray out Check the fuel spray prevention caps visually or with a finger to see if any of them has slipped off or the rubber portion is hardened If there is any loose bolt or hardened rubber ask your Komatsu distributor for replacement MAINTENANCE MAINTENANCE PROCEDURE 4 8...

Page 395: ...EANING KDPF Contact your Komatsu distributor for cleaning of the KDPF METHOD FOR CLEANING DEF TANK Ask your Komatsu distributor for cleaning of the DEF tank METHOD FOR CLEANING DEF TANK MOUNTING PORTION Ask your Komatsu distributor for cleaning of the mounting portion of the DEF tank MAINTENANCE PROCEDURE MAINTENANCE 4 82 ...

Page 396: ...ery 50 250 500 1000 2000 and 4000 hours service should be performed at the same time METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor for replacement of the fuel spray prevention caps MAINTENANCE MAINTENANCE PROCEDURE 4 83 ...

Page 397: ...E Maintenance for every 50 250 500 1000 and 4500 hours service should be performed at the same time METHOD FOR REPLACING DEF HOSE Ask your Komatsu distributor for replacement of the DEF hose MAINTENANCE PROCEDURE MAINTENANCE 4 84 ...

Page 398: ...SPECIFICATIONS 5 1 ...

Page 399: ... 2200 2200 ISO 9249 SAE J1349 net 125 168 2200 2200 A Overall length mm ft in 5480 18 0 B Overall height mm ft in 3180 10 5 C Overall width mm ft in 3250 10 8 Travel speed Quick shift mode Forward 1st 2nd 3rd km h MPH 3 4 5 6 9 0 2 1 3 5 5 6 Reverse 1st 2nd 3rd km h MPH 4 1 6 5 9 0 2 5 4 0 5 6 Travel speed Variable shift mode Forward km h MPH 0 8 to 9 0 0 5 to 5 6 Reverse km h MPH 0 8 to 9 0 0 5 t...

Page 400: ...00 ISO 9249 SAE J1349 net 125 168 2200 2200 A Overall length mm ft in 5480 18 0 B Overall height mm ft in 3180 10 5 C Overall width mm ft in 3860 12 8 Travel speed Quick shift mode Forward 1st 2nd 3rd km h MPH 3 4 5 6 9 0 2 1 3 5 5 6 Reverse 1st 2nd 3rd km h MPH 4 1 6 5 9 0 2 5 4 0 5 6 Travel speed Variable shift mode Forward km h MPH 0 8 to 9 0 0 5 to 5 6 Reverse km h MPH 0 8 to 9 0 0 5 to 5 6 SP...

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Page 402: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1 ...

Page 403: ... 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 performing the operation Use a crane when carrying heavy objects more than 25 kg 55 lb When removing a heavy part always place a support in position before removin...

Page 404: ...HANDLE HYDRAULIC RIPPER This ripper is applicable for D61EX GENERAL VIEW 1 Hydraulic cylinder 2 Link 3 Beam 4 Shank 5 Point 6 Support ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER 6 3 ...

Page 405: ...ound and set the work equipment lock lever to LOCK position The ripper control lever is used for operating the ripper a RAISE Ripper goes up b HOLD Ripper is stopped and held in this 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 HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS 6 4 ...

Page 406: ...reverse When turning the machine suddenly or traveling in reverse raise the shank from the ground surface When performing digging operations with only one shank always use the center shank Remove both side shanks The point end touches the ground at the start of an uphill and at the end of a downhill If the ground is hard at this time the ripper may be damaged To prevent this raise the shank to the...

Page 407: ...t is installed to protect the shank If the point is worn replace it according to the following procedure 1 Put a pin puller to the pin indicated by the arrow and hit it with a hammer to drive out the pin The pin comes off 2 Replace the point 3 Insert the pin halfway 4 Drive in the pin with the hammer Criteria Remedy Standard di mension mm in Repair limit mm in Wear a of rip per point 1 277 10 9 17...

Page 408: ...ustment of relief valve Check adjust Defective control valve abnormal pressure pre vention valve or valve spool Check repair Defective piston ring packing or valve Check repair Clogging inside piping Check repair Cylinder lacks holding power Leakage of oil from piping or hose Retighten Defective piston ring or packing Replace Defective piston valve Check repair Defective valve spool Check repair D...

Page 409: ...rod end pin 1 place 3 Link pin 8 places METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK ADDING OIL 1 Place the machine on a level ground and lower the work equipment to the ground If the machine is inclining make it level 2 Make the blade perpendicular and lower it to the ground 3 Make the ripper point touch the ground 4 Stop the engine 5 Check oil level in hydraulic tank For details see OPERATION...

Page 410: ...gle power tilt dozer Machine with ripper Item Unit D61EX 24 Machine weight kg lb 20140 44409 Ripper unit weight kg lb 1780 3925 A Overall length mm ft in 6765 22 2 Number of shanks 3 ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER 6 9 ...

Page 411: ...61PX GENERAL VIEW 1 Center blade 2 Folding blade right and left 3 Lock plate 4 Offset lock pin 5 Hinge pin 6 Shim for offset lock pin 7 Shim for hinge pin 8 Lock plate fixing pin 9 Lock pin 10 Lock plate HANDLE 3m WIDTH BLADE ATTACHMENTS AND OPTIONS 6 10 ...

Page 412: ...erve all related laws and regulations and be careful to assure safety TRANSPORTATION PROCEDURE As a basic rule always transport the machine on a trailer When transporting the machine choose the transportation method in reference to the weight and dimensions of machine Note that the mass and dimensions for transportation shown in SPECIFICATIONS depend on the types of shoe blade etc The 3 m wide bla...

Page 413: ...be caught be tween the blade and track shoe Do not put your fingers into the pin hole of the offset lock pin The folding blade may turn and your fingers may be caught Do not perform any work in between the blade and track while the lock plate has been removed The folding blade may turn and you may be caught between the blade and track k k CAUTION Do not tilt or angle the blade when it is folded If...

Page 414: ...lock plate 7 approximately 100 backward 11 Rotate folding blade 5 180 backward 12 Fix folding blade 5 by setting the hole of lock plate 7 to lock plate fixing pin 8 on folding blade 5 13 Fix lock plate 7 and folding blade 5 by using lock pin 6 14 Install removed offset pins 1 4 pieces shims 3 2 sets and lock plates 2 4 pieces to holes 9 of center blade REMARK Install removed offset lock pins 1 shi...

Page 415: ... center blade are worn folding or unfolding of the blade becomes diffi cult Replace and adjust shims 1 and 2 in the bosses at both ends according to the following procedure 1 Stop the machine on a level ground 2 Raise the blade and set it in parallel with the machine 3 If shims 1 and 2 at the bosses 4 places of the center blade are worn remove them 4 Measure clearances A and B in the bosses of the...

Page 416: ...er tilt dozer 3m wide blade Item Unit D61PX 24 Overall length When unfolded mm ft in 3860 12 8 Overall length When folded mm ft in 2990 9 10 Overall blade width When folded mm ft in 2960 9 9 ATTACHMENTS AND OPTIONS HANDLE 3m WIDTH BLADE 6 15 ...

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Page 418: ...REPLACEMENT PARTS 7 1 ...

Page 419: ...ion like deformation or cracking replace the clamps at the same time as the hoses Also perform the following checks with hydraulic hoses which need not to be replaced periodically Tighten all loose hoses 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 defined life parts DEFIN...

Page 420: ... air filter 12Y 979 1174 Filter 2 Recirculation air filter 12Y 979 6180 Filter 2 Fuel main filter 600 319 3750 Cartridge with cap 1 Every 1000 hours Hydraulic tank breather 421 60 35170 Element 1 DEF tank breather 421 60 35170 Element 1 Fuel tank breather 421 60 35170 Element 1 Hydraulic oil filter 22P 60 21161 Element 1 Every 2000 hours 07000 12135 O ring 1 KCCV filter 600 331 2900 Element 1 HST ...

Page 421: ...NOTICE When handling parts that weigh more than 25 kg 55 1 lb remember that they are heavy objects and take the necessary care CONSUMABLE PARTS REPLACEMENT PARTS 7 4 ...

Page 422: ...led high pressure fuel injection device and emission gas control system KDPF Since the high pressure fuel injection device requires high precision parts and lubrication if low viscosity fuel with low lubricating ability is used its durability may drop con siderably And using fuel with high sulfur content can dete riorate the engine parts and KDPF catalyzer inducing fail ures decrease of the life a...

Page 423: ...lubrication interval Even if the same symbol is used in the lubrication chart the recommended genuine oil may differ according to the lubrication points and the ambient temperature The symbols used in the lubrication standard chart are explained as follows RECOMMENDED FUEL COOLANT AND LUBRICANT REPLACEMENT PARTS 7 6 ...

Page 424: ...eplace final drive case Replace engine oil filter Replace hydraulic oil filter and clean hy draulic tank strainer Replace breather element in hydraulic tank Replace fuel main filter Replace KCCV filter Replace breather element in fuel tank Check oil level in pivot shaft and add oil Replace fuel prefilter Replace HST oil filter Replace DEF tank breather element Replace DEF filter REPLACEMENT PARTS ...

Page 425: ...0 4 122 Lithium EP grease G2 LI KES 10 50 14 122 Cooling system Non Amine Engine Coolant AF NAC Note 3 AF NAC KES 30 50 22 122 Fuel tank Diesel fuel ASTM D975 No 1 D S15 30 20 22 68 ASTM D975 No 2 D S15 0 50 32 122 DEF tank DEF Note 4 DEF 30 50 22 122 KES Komatsu Engineering Standard ASTM American Society of Testing and Material Reservoir Specified capacity Refill capacity Liter US gal Liter US ga...

Page 426: ...ines are supplied with Non Amine Engine Coolant AF NAC Non Amine Engine Coolant AF NAC has excellent anti corrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Non Amine Engine Coolant AF NAC is strongly recommended wherever available 2 For the density of Non Amine Engine Coolant AF NAC see Coolant density table Non Amine Engine Coolant AF NAC is suppli...

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Page 428: ...mer Set 3 75 AUX 3 235 Avoid mixing oil 4 3 B Backup alarm operation Check 3 171 Band AUX selector button 3 233 Basic operation of machine monitor 3 6 Battery 3 246 Battery Check electrolyte level from side 4 47 Battery Check electrolyte level impossible from side 4 48 Battery Handle 2 31 Battery Remove Install 3 252 Battery disconnect switch 3 114 Battery electrolyte Check level 4 46 Beware of as...

Page 429: ... machine 3 216 Door damper Replace 4 34 Door hinge Lubricate 4 34 Door latch Check 4 34 Door lock striker Check 4 35 Door open lock 3 107 Door wiper Replace 4 37 Dozing work 3 217 Dust indicator 3 117 Dust indicator Check 3 159 Dusty jobsite 4 3 E ECO gauge Set target fuel consumption value 3 69 ECO gauge drawbar pull gauge 3 41 ECO guidance record Check 3 63 Electric wiring Check 3 159 Electrical...

Page 430: ...p 3 227 Fuel tank breather Clean 4 33 Fuel tank breather element Replace 4 60 Fuel coolant and lubricants according to ambient temperature Use 7 8 Function switches 3 47 Function switches and guidance icons 3 43 Fuse 3 110 Fusible link 3 112 G Gauges Watch 3 215 Gear Shift 3 203 Gear shift mode 3 47 Gear shift mode selector switch 3 46 Gearshift mode Change 3 203 General character and precautions ...

Page 431: ... 241 Machine Set each item Save memory 3 51 Machine Shift gear 3 203 Machine Start 3 199 Machine Start Travel forward and reverse Stop 3 199 Machine Start after long term storage 3 249 Machine Steer 3 208 Machine Stop 3 202 Machine Switch travel direction 3 207 Machine Transport 3 239 6 11 Machine Travel on load 3 239 Machine Turn during forward travel 3 208 Machine Turn gradually during forward t...

Page 432: ...recautions for DEF 2 37 Precautions for discharged battery 3 251 Precautions for disposing of waste materials 2 36 Precautions for fire hazard and leakage 2 37 Precautions for floating operation 3 216 Precautions for getting on or off machine 2 13 Precautions for high voltage 2 34 Precautions for high pressure fuel 2 33 Precautions for high pressure grease when adjusting track tension 2 34 Precaut...

Page 433: ...nting bolt Check for looseness 4 64 S Safety information 1 3 Safety labels 2 2 Safety rules for transporting machine 3 239 Safety related equipment 2 9 Sash glass intermediate lock 3 107 SCR information 3 77 Screen Adjust 3 80 Seat Adjust in fore and aft direction 3 172 3 175 3 178 Seat Adjust tilt 3 173 3 175 3 178 Seat Adjust weight and height 3 173 3 176 Seat Heat 3 174 3 177 Seat Recline 3 172...

Page 434: ...amper Check 4 72 Visibility from operator s seat 1 5 Volume control button 3 233 W Warning display 3 13 Warning tags Use 2 19 Water pump Check 4 78 Water separator Check Drain water and sediment 3 153 Water separator caution lamp 3 27 Wear well fitting clothes and protective equipment 2 9 Weight on seat Adjust 3 179 When required 4 15 6 14 Window washer fluid Check level Add 4 35 Window washer flu...

Page 435: ...D61EX 24 D61PX 24 BULLDOZER Form No TEN00709 03 2017 KOMATSU All Rights Reserved Printed in Japan 03 2017 ...

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