Page 1 This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it. NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.
Page 2 FOREWORD CALIFORNIA CALIFORNIA Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its Battery posts, terminals and related accessories contain lead constituents are known to the State and lead compounds, chemicals of California to cause cancer, birth known to the State of California de fe c ts , a nd o th e r re p ro d u cti v e to cause cancer, birth defects and reproductive harm.
Page 3 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.
Page 4: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 5: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Dozing work • Leveling work • Cutting into hard or frozen ground or ditching • Works of felling trees and removing stumps For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS”.
Page 6: Visibility From Operator's Seat
FOREWORD INTRODUCTION VISIBILITY FROM OPERATOR'S SEAT The visibility of this machine required by visibility standards (ISO 5006) are shown in the drawing below. Proximity visibility This machine maintains a proximity visibility of a height of 1.5 m {4 ft 11 in} at a point 1 m {3 ft 3 in} away from the outside surface of the machine.
Page 7: Engine Technology To Conform Exhaust Gas Emission
Catalytic Reduction (SCR) to conform EPA Tier4 Final emission regulation in North America. • Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process to burn the soot is performed automatically to keep the filtering performance of KDPF high.
Page 8: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE It is located at front left of the operator's seat.
Page 9: Service Meter Location
PRODUCT INFORMATION FOREWORD SERVICE METER LOCATION This is 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...
Page 10: Table Of Contents
FOREWORD TABLE OF CONTENTS TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 SAFETY INFORMATION .......................... 1-3 INTRODUCTION ............................1-4 MAIN USE OF MACHINE ........................1-4 DIRECTIONS OF MACHINE......................1-4 VISIBILITY FROM OPERATOR'S SEAT .................... 1-5 ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION ............. 1-6 PRODUCT INFORMATION........................
Page 11 OTHER TROUBLE......................... 3-256 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 12 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 ........................6-2 PRECAUTIONS FOR SAFETY ......................6-2 HANDLE HYDRAULIC RIPPER........................
Page 13 CONSUMABLE PARTS LIST ......................7-3 RECOMMENDED FUEL, 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 1-12...
Page 14: Safety
SAFETY Please 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.
Page 15: Safety Labels
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. •...
Page 16: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS (1) Caution for operation, inspection and maintenance (9) Stop rotation during inspection and maintenance (2) Caution for safety at rear (10) Caution for approaching while moving machine (3) Caution when leaving operator's seat (11) Prohibition of start by short-circuiting (4) Caution for high-temperature coolant (12) Caution for handling battery...
Page 17: Contents Of Safety Labels
SAFETY LABELS SAFETY CONTENTS OF SAFETY LABELS Caution for operation, inspection and maintenance “09651-03001” Caution for safety at rear “09802-13000”...
Page 18 SAFETY SAFETY LABELS Caution 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”...
Page 19 SAFETY LABELS SAFETY Caution for adjusting track tension “09657-03003” The safety label is attached to the back of the cover of the track adjustment window. Caution for handling cable “09808-03001” WARNING Improper use of jumper cables and battery cables can cause an explosion resulting in serious injuly or death.
Page 20 SWALLOWED,INHALED, or IN EYE: immediately call a POISON CENTER or consult doctor/physician. if on CLOTHES or SKIN: wash immediately with water. Komatsu America Corp.1701 Golf Rd. Rolling Meadows,IL 60008.(731)635 6321 09664-30014 Caution for handling ROPS/FOPS...
Page 21 SAFETY LABELS SAFETY 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”...
Page 22: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 23 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY KEEP MACHINE CLEAN • If you get on or off the machine or perform inspection and maintenance on the machine with mud or oil, you may slip and fall, and it is dangerous. Wipe off any mud or oil from the machine. Always keep the machine clean.
Page 24: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE PRECAUTIONS TO PREVENT FIRE ACTIONS IF FIRE OCCURS • Turn the starting switch to OFF position, and stop the engine. • Use the handrails and steps to escape from the machine. •...
Page 25 Fire around the machine due to highly heated exhaust gas 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).
Page 26: Precautions When Getting On Or Off Machine
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. •...
Page 27: Do Not Get Caught In Work Equipment
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT When standing up from the operator's seat to adjust the opera- tor's seat, 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.
Page 28: Precautions Related To Protective Structures
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu distributor.
Page 29: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 30 SAFETY PRECAUTIONS FOR OPERATION DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always observe the following.
Page 31 Prohibit other personnel from coming close to the machine during operation. • Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. 2-18...
Page 32: Start Engine
SAFETY PRECAUTIONS FOR OPERATION START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine. If the warning tag is ignored and the machine is operated, the person performing inspection or maintenance may be caught in the rotating parts or moving parts.
Page 33 PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN STARTING ENGINE The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the following. • Start the engine only while sitting down in the operator's seat. •...
Page 34: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly, the machine will be unable to display its full perform- ance. It is dangerous and may cause serious personal injury or death. When performing the checks, move the machine to a wide area with no obstructions, and pay careful attention to the surroundings.
Page 35 PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN TRAVELING Serious personal injury or death can result from tipping over of the traveling machine or its accidental contact. Always observe the following. • When driving the machine or performing operations, always keep a safe distance from people, structures, or other machines to avoid coming into contact with them.
Page 36 SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side, always observe the following. • Never turn the key in the starting switch to OFF position when the machine is traveling downhill. If the engine stops when the machine is traveling, it may become impossible to operate the steering, and this may cause serious per- sonal injury or death.
Page 37 PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES • Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ma- chine, and do not perform abrupt lever operation. Machine may slip even on a slight slope. Be particularly careful when working on slopes.
Page 38: Precautions For Transportation
• This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is wrong when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 39: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY TOWING AND BEING TOWED PRECAUTIONS FOR TOWING AND BEING TOWED Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or death.
Page 40: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 41 PRECAUTIONS FOR MAINTENANCE SAFETY STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death. Always observe the fol- lowing.
Page 42 SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent accident, do not perform maintenance with the engine running. When it is necessary to perform the maintenance with the engine running, always observe the following. • One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 43 PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS WHEN WORKING ON MACHINE • When performing maintenance work on the machine, maintain the foothold clean and orderly to prevent falling. Always observe the followings. • Avoid spilling of oil and grease. • Do not litter the tools. •...
Page 44: Precautions For Check And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR CHECK AND MAINTENANCE TURN BATTERY DISCONNECT SWITCH TO OFF POSITION In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key. If you check and handle battery without turning battery disconnect switch to OFF position, serious personal in- jury or death by such as an electric shock may occur.
Page 45 PRECAUTIONS FOR MAINTENANCE SAFETY • If battery electrolyte gets on your clothes or skin, wash it off immediately with large amounts of water. Danger of sparks Sparks may be generated and they can cause a fire. Always observe the following. •...
Page 46 If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 47 PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR HIGH VOLTAGE When the engine is running and immediately after it is stopped, high voltage is generated inside the engine controller and the engine injector, and there is danger of electric shock. Never touch the inside of the engine controller or the injector part of the engine.
Page 48 If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. If it is necessary to disassemble it, ask your Komatsu distributor to perform the work. HANDLE ACCUMULATOR This machine is equipped with an accumulator.
Page 49 PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution, pay full attention to the way to dispose of waste materials. • Always drain the oil from your machine in containers. Nev- er drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.
Page 50: Precautions For Def
SAFETY PRECAUTIONS FOR DEF PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 52: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 53: General View
(7) Work equipment frame (2) Angle cylinder (8) Tilt cylinder (3) Front cover (9) Lift cylinder (4) ROPS cab (10) Track frame (5) Sprocket (11) Track (6) Idler (12) Radiator grille (13) Komatsu Diesel Particulate Filter (hereinafter (14) SCR KDPF)
Page 54: Controls And Gauges Names
OPERATION GENERAL VIEW (15) Komatsu Closed Crankcase Ventilation (hereafter (18) DEF tank KCCV) ventilator (19) System operating lamp (16) DEF injector (20) Battery disconnect switch (17) DEF pump CONTROLS AND GAUGES NAMES (1) Air conditioner switch (10) Starting switch (2) Cigarette lighter...
Page 55 GENERAL VIEW OPERATION MACHINE MONITOR EQUIPMENT NAME AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Pedal mode selector switch (16) Operating mode display (2) Buzzer cancel switch (17) Steering mode display (3) Operating mode selector switch (18) Preheating pilot lamp (4) Reverse travel speed setting switch (19) Fan reverse rotation pilot lamp...
Page 56: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen (1) Warning display...
Page 57 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION • When the starting switch is turned to ON position, opening screen GG is displayed. • After opening screen GG is displayed for 2 seconds, the screen switches to camera image FF. •...
Page 58 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 reply to it.
Page 59 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-...
Page 60 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.
Page 61 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB- NORMAL SITUATION • If there is any abnormality when starting the engine, the check before starting screen BB changes to the maintenance time warning screen CC, warning screen FF-1, or error screen EE. •...
Page 62 OPERATION EXPLANATION OF COMPONENTS If there is any 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. 3-11...
Page 63 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any abnormality 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.
Page 64 OPERATION EXPLANATION OF COMPONENTS WARNING DISPLAY NOTICE Appearance of any of action levels “L01” to “L04” on the machine monitor indicates presence of an ab- normality of the machine. Take appropriate actions following the list of action level displays and required actions. The caution lamp that lights up in red when an action level is displayed warns operator to stop the ma- chine urgently, stop or pause the current operation.
Page 65 │ no load or stop it. Sounds inter- Lights up in │ mittently If the condition is not improved, ask your Komatsu distributor │ for inspection and maintenance. │ Some functions may be restricted from use, but the machine ↓...
Page 66 OPERATION EXPLANATION OF COMPONENTS CAUTION LAMP LIST NOTICE • These caution lamps do not guarantee the condition of the machine. Do not simply rely on the caution lamp when performing checks before starting (start-up inspec- tion). Always get off the machine and check each item directly. •...
Page 67 EXPLANATION OF COMPONENTS OPERATION Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Abnormal Accumulated KDPF soot accumulation caution lamp (L03) (L01) Abnormal Sensing is DEF level caution lamp Normal disabled (L04, L03) Abnormal Abnormal DEF system caution lamp (L04, L03) (L01)
Page 68 OPERATION EXPLANATION OF COMPONENTS Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Clogged Air cleaner clogging caution lamp (L01) Due time is Maintenance time caution lamp Notice over Seat belt is Seat belt caution lamp not fastened For the meaning of each caution lamp and the action to take for it, see the section of each caution lamp.
Page 69 EXPLANATION OF COMPONENTS OPERATION CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated, “!” is displayed on top of switch F5. While “!” is displayed, press switch F5 to shift the monitor dis- play screen to the “Current Abnormality” screen. Take appropriate actions according to the displayed message.
Page 70 OPERATION EXPLANATION OF COMPONENTS ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature. When abnormal The caution lamp lights up in red and indicates action level “L02”. The engine coolant temperature is abnormally high. While this lamp is lit, the overheat prevention system is auto- matically actuated and the engine speed drops.
Page 71 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 72 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 maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 73 For replacement of the filter element, see “METHOD FOR CHANGING OIL IN HYDRAULIC TANK, REPLACING HYDRAULIC OIL FILTER ELEMENT, REPLACING HST OIL FILTER CARTRIDGE, AND CLEANING HYDRAULIC TANK STRAINER”. If the caution lamp does not go out, ask your Komatsu distributor for inspection and maintenance. 3-22...
Page 74 Some functions may be restricted from use, but the machine can operate. When you finish the operation, always perform the inspection and maintenance. Ask your Komatsu distributor for the inspection and maintenance as needed. KDPF SOOT ACCUMULATION CAUTION LAMP The KDPF soot accumulation caution lamp warns that soot is accumulated in KDPF or the filtering function of KDPF has low- ered abnormally.
Page 75 EXPLANATION OF COMPONENTS OPERATION DEF LEVEL CAUTION LAMP DEF level caution lamp alerts when DEF tank level becomes low. Whenever the caution lamp lights up in red, immediately add DEF. Fault conditions that result in activation of the Inducement strat- egy for engine derates to prompt to maintain or repair the emis- sion control system.
Page 76 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 action level “L01” is displayed The caution lamp lights up in yellow.
Page 77 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 action level “L01” is displayed The caution lamp lights up in yellow.
Page 78 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 distributor for inspection and main- tenance. WATER SEPARATOR CAUTION LAMP The water separator caution lamp warns that water is accumu- lated in the water separator.
Page 79 • The lighting time of maintenance due time notice (yellow) has been initially set to 30 hours, but it can be changed. To change the setting, ask your Komatsu distributor. • For operations on the “Maintenance” screen, see “MAIN- TENANCE SCREEN SETTING”.
Page 80 OPERATION EXPLANATION OF COMPONENTS SEATBELT CAUTION LAMP The seat 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”.
Page 81 EXPLANATION OF COMPONENTS OPERATION PILOT DISPLAY AND METER DISPLAY Pilot display (1) Engine stop pilot lamp (8) Steering mode display (2) Parking brake pilot lamp (9) Preheating pilot lamp (3) Work equipment lock pilot lamp (10) Fan reverse rotation pilot lamp (4) Aftertreatment devices regeneration pilot lamp (11) FLOAT mode pilot lamp (5) Aftertreatment devices regeneration disable pilot...
Page 82 ON position. MESSAGE DISPLAY The User Message is displayed when there is a message from Komatsu. To read the message, see “MESSAGE DISPLAY”. Lights up in green (A): There is unread message. Lights up in blue (B): There is any read message to which no reply has been made.
Page 83 EXPLANATION OF COMPONENTS OPERATION AFTERTREATMENT DEVICES REGENERATION PILOT LAMP CAUTION • Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regeneration. Stay away from the exhaust pipe outlet to prevent yourself from getting burnt. Also, keep combustible materials away from the exhaust pipe outlet to prevent a fire. •...
Page 84 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE PILOT LAMP The parking brake pilot lamp lights up when the parking brake lever is in LOCK position. It goes out when the parking brake lever is set to FREE posi- tion. When the parking brake lever needs to be set to LOCK posi- tion, the parking brake pilot lamp flashes.
Page 85 EXPLANATION OF COMPONENTS OPERATION GUIDANCE DISPLAY The guidance for energy saving operation to reduce the fuel consumption may be displayed during operation. The details of the guidance are as follows: Idling stop guidance If no operation is performed for more than 5 minutes, and the engine is idling, the idling stop message is displayed on the machine monitor.
Page 86 OPERATION EXPLANATION OF COMPONENTS Overload prevention guidance If the machine is overloaded during work, overload prevention message is displayed on the machine monitor. Fuel consumption can be reduced by avoiding shoe slip or op- erating the machine in the green zone of ECO gauge. Overload prevention guidance goes out more than 5 seconds later or when switch F5 is pressed.
Page 87 EXPLANATION OF COMPONENTS OPERATION Guidance for engine stop operation during the aftertreatment devices regenera- tion Immediately after starting aftertreatment devices regeneration, the information about engine stop operation during the after- treatment devices regeneration is displayed on the machine monitor. The guidance for engine stop operation during regeneration of the aftertreatment devices goes out 10 seconds later or when switch F5 is pressed.
Page 88 OPERATION EXPLANATION OF COMPONENTS METER DISPLAY MULTI GAUGE The multi gauge can display various items. As an example, dis- play of the engine tachometer is explained below. If the indicator is in green range during operations, it is normal. When the indicator goes beyond (A) of red range during opera- tions, the engine speed is too high.
Page 89 EXPLANATION OF COMPONENTS OPERATION HYDRAULIC OIL TEMPERATURE GAUGE Hydraulic oil temperature gauge shows the hydraulic oil tem- perature. If the indicator is in green range during operations, it is normal. If the indicator goes beyond red range (A) during operations, the overheat prevention system operates.
Page 90 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE Fuel gauge shows the amount of fuel in the fuel tank. The indicator should be in the green range during operations. When the indicator comes close to red range (A) during opera- tion, check and add fuel. (A) to (B): Red range (A) to (C): Green range REMARK...
Page 91 EXPLANATION OF COMPONENTS OPERATION SERVICE METER / CLOCK The service meter / clock shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even when the machine is not moving. The service meter advances 0.1 every 6 operation minutes, regardless of the engine speed.
Page 92 OPERATION EXPLANATION OF COMPONENTS ECO GAUGE / DRAWBAR PULL GAUGE The ECO gauge/ drawbar pull gauge displays ECO gauge (in- stantaneous fuel consumption) (C) or drawbar pull gauge (work load) (D). The instantaneous fuel consumption means the fuel consump- tion rate at each moment, which varies with the work load and engine speed.
Page 93 EXPLANATION OF COMPONENTS OPERATION DEF LEVEL GAUGE DEF level gauge indicates the remaining level of DEF. If the indicator is in green range during operations, it is normal. If the indicator comes close to (A) of red range during opera- tion, check and add DEF.
Page 94 OPERATION EXPLANATION OF COMPONENTS MONITOR SWITCHES (1) Function switch (4) Pedal mode selector switch (2) Buzzer cancel switch (5) Gear shift mode selector switch (3) Operating mode selector switch (6) Reverse travel speed setting switch FUNCTION SWITCHES AND GUIDANCE ICONS •...
Page 95 EXPLANATION OF COMPONENTS OPERATION (B) Switch F3: Camera image selector switch. (C) Switch F4: Service meter / clock display selector switch (D) Switch F5: Current Abnormality display switch (Only while caution lamp is lit) (E) Switch F5: Energy saving (ECO) guidance erase switch (While ECO guidance is displayed) (F) Switch F6: User menu display switch Guidance icons and their functions differ with the contents of the displayed screen, but representative guidance...
Page 96 OPERATION EXPLANATION OF COMPONENTS (K) Switch F5: Cancels any change and returns to the previous screen. (L) Switch F6: Decides any selection and changes contents and advances to the next screen. REMARK • Even if some guidance icons look the same, their display positions and corresponding function switches may differ in accordance with the screens to be displayed.
Page 97 EXPLANATION OF COMPONENTS OPERATION PEDAL MODE SELECTOR SWITCH The pedal mode selector switch is used to switch the pedal mode between decelerator mode and brake mode. If the decelerator/brake pedal is depressed in decelerator mode, the travel speed and engine speed lower. If the decelerator/brake pedal is depressed in brake mode, the travel speed lowers but the engine speed does not lower.
Page 98 OPERATION EXPLANATION OF COMPONENTS FUNCTION SWITCHES The operation of the function switches in the standard screen CUSTOMIZE SWITCH CAUTION To ensure safety, always stop the machine before operating the customize switch. Press switch F1, and “Mode Select” screen is displayed. On “Mode Select”...
Page 99 EXPLANATION OF COMPONENTS OPERATION PEDAL MODE Select “Pedal Mode” on “Mode Select” screen, and press switch F6. Pedal mode can be switched in accordance with the operation. Pedal mode can also be switched with the pedal mode selector switch. REVERSE TRAVEL SPEED SETTING Select “Reverse Travel Speed Setting”...
Page 100 OPERATION EXPLANATION OF COMPONENTS BLADE MODE Select “Blade Mode” on “Mode Select” screen, and press switch F6. Blade mode can be changed according to the operation. By setting to “FAST” mode, starting of operation for RAISE and LOWER becomes quick. By setting to “FINE”...
Page 101 EXPLANATION OF COMPONENTS OPERATION 2ND TRAVEL SPEED SETTING Select “2nd Travel Speed Setting” on “Mode Select” screen, and press switch F6. 2nd travel speed in quick shift mode can be selected out of 5 levels according to the operation. 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...
Page 102 OPERATION EXPLANATION OF COMPONENTS 3RD TRAVEL SPEED SETTING Select “3rd Travel Speed Setting” on “Mode Select” screen, and press switch F6. 3rd travel speed in quick shift mode can be selected out of 3 levels according to the operation. You can increase or decrease the speed in 1 level each. 0: Increases 1 level from preset 3rd travel speed -1: Preset 3rd travel speed -2: Decreases 1 level from preset 3rd travel speed...
Page 103 EXPLANATION OF COMPONENTS OPERATION Check the setting of each item (on the left of the screen). Press switch F3 or F4 to move the yellow cursor to a mem- ory number (“M1” to “M5”) to save, and press switch F6. The setting is saved by the above operation.
Page 104 OPERATION EXPLANATION OF COMPONENTS CAMERA IMAGE SELECTOR SWITCH On the standard screen, press switch F3 to switch to the cam- era image display. Press switch F3 while camera image is displayed, and the screen returns to the standard screen. Other mode operations while camera image is displayed Even when the camera image is displayed, it is possible to operate following modes.
Page 105 EXPLANATION OF COMPONENTS OPERATION • Press the reverse travel speed setting switch to set the re- verse travel speed. When the reverse travel speed is set, the screen returns automatically to the standard screen. • It is possible to stop the alarm buzzer for the warning item where there is an abnormality, by pressing the buzzer can- cel switch.
Page 106 OPERATION EXPLANATION OF COMPONENTS • If the caution lamp is displayed, press switch F3 to return to the standard screen, and check the content of the error or warning display. While the caution lamp is flashing, if no lever is operated for 10 seconds or more, the screen automatically returns to the standard screen.
Page 107 EXPLANATION OF COMPONENTS OPERATION SERVICE METER/CLOCK DISPLAY SELECTOR SWITCH By pressing switch F4, you can switch the service meter and clock display on the standard screen. If you press 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.
Page 108 OPERATION EXPLANATION OF COMPONENTS METHOD FOR USING MULTI GAUGE The multi-gauge can display the following items. Multi-gauge selection item Remarks Engine speed There is a caution Machine speed Work equipment pump pressure Battery voltage There is a caution Drawbar pull Clock display An approximate value indicated by the multi-gauge is as fol- lows.
Page 109 When the pointer is in green range during operation, it is normal. If the 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.
Page 110 OPERATION EXPLANATION OF COMPONENTS USER MENU DISPLAY SWITCH On the standard screen, press switch F6 to display the user menu screen on which you can make various settings for the machine in the monitor display. USER MENU The user menu consists of the following kinds. Press switches F1 and F2 to move to right and left for selecting menu screens.
Page 111 EXPLANATION OF COMPONENTS OPERATION (b) “Machine Setting” • Fan reverse mode • Auto idle stop timer setting (c) “Aftertreatment Devices Regeneration” • Setting for regeneration disable • Operation of manual stationary regeneration (d) “SCR Information” • Check of DEF level •...
Page 112 OPERATION EXPLANATION OF COMPONENTS (g) Mail Check • Check of mail contents and reply to mail Operation on user menu screen On the user menu screen, it is possible to perform the following operations with switches F1 to F6. F1: Moves to the left menu. When on the left end menu, it moves to the right end menu.
Page 113 EXPLANATION OF COMPONENTS OPERATION ENERGY SAVING GUIDANCE Each item of “Energy Saving Guidance” menu (a) is used for displaying and setting the notification relevant to energy saving. CHECK OPERATION RECORDS Select “Operation Records” (1) from “Energy Saving Guidance” menu screen, then press switch F6. On “Operation Records”...
Page 114 OPERATION EXPLANATION OF COMPONENTS CHECK ECO GUIDANCE RECORD Select “ECO Guidance Records” (2) from “Energy Saving Guid- ance” screen, then press switch F6. On the “ECO Guidance Records” menu, display the frequency of display of the ECO guidance on a daily basis or during the split measurement period.
Page 115 EXPLANATION OF COMPONENTS OPERATION Operation on “Average Fuel Consumption Record” screen On “Average Fuel Consumption Record” screen, it is possible to perform the following operations with switches F1, F2, and F1: Clears the graph data. F2: Switches graphical displays of the average fuel consump- tion.
Page 116 OPERATION EXPLANATION OF COMPONENTS Deleting the Average Fuel Consumption Record When switch F1 (CLEAR) is pressed, the reconfirmation screen shown in the figure is displayed. When the switch F6 is pressed on the reconfirmation screen, graphs of data during last 12 hours and last 7 days are both deleted, and the screen returns to “Average Fuel Consumption Record”...
Page 117 EXPLANATION OF COMPONENTS OPERATION SET DISPLAY OF FUEL CONSUMPTION GAUGE It is possible to change the display of fuel consumption gauge (5) and the setting of Display/Non-display. Select “Average Fuel Consumption Display” (6) from “Con- figurations” screen, then press switch F6. On this screen, it is possible to perform the following oper- ations with switches F3 to F6.
Page 118 OPERATION EXPLANATION OF COMPONENTS REMARK When you select the split measurement, measurement stop switch F1 (“STOP”) is displayed on 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”...
Page 119 EXPLANATION OF COMPONENTS OPERATION SWITCH DISPLAY/NON-DISPLAY OF ECO GAUGE AND DRAWBAR PULL GAUGE You can specify the item to be displayed on display (7) of the standard screen. Select “ECO Gauge display” (8) from “Configurations” screen, then press switch F6. The “ECO Gauge Display”...
Page 120 OPERATION EXPLANATION OF COMPONENTS SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE It is possible to change the target fuel consumption value (the upper limit value of the green range) of the ECO gauge (7). Select “ECO Gauge Display Fuel Target Value” (9) on “Configurations”...
Page 121 EXPLANATION OF COMPONENTS OPERATION SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE It is possible to change the setting of Display/Non-display of ECO guidance (10). Select “ECO Guidance display” (11) from “Configurations” screen, then press switch F6. “ECO Guidance Display” setting screen appears. ON: Displays ECO Guidance (10) on the standard screen.
Page 122 OPERATION EXPLANATION OF COMPONENTS SWITCH DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY IS OFF It is possible to change the setting of Display/Non-display of guidance (12) when the starting key is turned off. Select “ECO Guidance Display at Key OFF” (13) from “Configurations”...
Page 123 EXPLANATION OF COMPONENTS OPERATION MACHINE SETTINGS Each item of this menu (b) is used for setting items of machine. REVERSE HYDRAULIC FAN NOTICE • After stopping the engine, check around the engine for sticking dry leaves or dirt. In particular, carefully check around the exhaust manifold, turbocharger, KDPF, and SCR for stick- ing dirt which can cause a fire.
Page 124 OPERATION EXPLANATION OF COMPONENTS Perform the engine warm-up operation. If the warm-up operation is not performed, the air flow may be insufficient. After finishing the warm-up operation, set the fuel control dial to Low idle (MIN) position. Stop the engine. Open the hydraulic tank inspection cover and fuel tank inspection cover.
Page 125 EXPLANATION OF COMPONENTS OPERATION After the engine is started, the machine monitor screen displays as shown in the figure. If the parking brake lever or work equipment lock lever is set to FREE position while the fan is rotated in reverse, the screen shown in the figure is displayed.
Page 126 OPERATION EXPLANATION OF COMPONENTS AUTO IDLE STOP TIMER SETTING The auto idle stop function stops the engine automatically when the engine is operated continuously at idle with the lock lever in LOCK position for a set time. The auto idle stop function operates when the following conditions are satisfied. •...
Page 127 EXPLANATION OF COMPONENTS OPERATION When countdown reaches 0, the engine stops and the screen changes to the “Auto Idle Stop in Operation” screen. To prevent battery discharging, turn off unnecessary switches. REMARK While the auto idle stop 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...
Page 128 OPERATION EXPLANATION OF COMPONENTS AFTERTREATMENT DEVICES REGENERATION Each item of “Aftertreatment Devices Regeneration” menu (c) is to make settings 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”...
Page 129 EXPLANATION OF COMPONENTS OPERATION MAINTENANCE SCREEN SETTING Each item of setting menu (e) on “Maintenance” screen is used for displaying and setting the notification relevant to mainte- nance. The items on the “maintenance” display are as follows. Air Cleaner Cleaning or Change Coolant Change Fuel Prefilter Change Engine Oil Change...
Page 130 • If you want to change the setting for the maintenance time or maintenance notice time (initial setting: 30 hours), consult your Komatsu distributor. Operations on “Maintenance Due Time Reset” screen On “Maintenance” screen, if switch F6 is kept pressed for 1.5 seconds or more, the screen changes to “Mainte- nance Due Time Reset”...
Page 131 EXPLANATION OF COMPONENTS OPERATION MONITOR SETTINGS Each item of “Monitor Setting”menu (f) is to make settings for the monitor. SCREEN ADJUSTMENT Use the “Screen Adjustment” menu to adjust brightness of the monitor screen. Select “Screen Adjustment” (1) on the “Monitor Setting” menu screen, then press switch F6.
Page 132 The guide lines indicate blade width lines and a line 5 m {16 ft 5 in} away from the rear of the machine. When changing the blade, ask your Komatsu distributor for adjustment of the camera screen. Select camera “Screen Adjustment (Camera)” on the “Monitor Setting”...
Page 133 EXPLANATION OF COMPONENTS OPERATION Use switches F2 to F6 to adjust brightness of the screen. F2: Resets an adjusted value to default value. F3: Moves the indicator to the left by one notch. F4: Moves the indicator to the right by one notch. F5: Cancels the change and returns the screen to “Screen Adjustment (Camera)”...
Page 134 OPERATION EXPLANATION OF COMPONENTS SET GUIDE LINE DISPLAY MODE Select “Guide Line Display Mode” on “Screen Adjustment (Camera)” menu. Press switch F6. “Guide Line Display Mode” setting screen is displayed. • “OFF”: Guide lines (Outline (A), Center Line (B)) are not displayed.
Page 135 EXPLANATION OF COMPONENTS OPERATION CLOCK ADJUSTMENT “Clock Adjustment” menu is used to change the setting of the clock displayed on the standard screen of the monitor. Select “Clock Adjustment” (3) on “Monitor Setting” menu screen. Press switch F6. The screen changes to “Clock Adjustment” screen. The following 5 items can be changed.
Page 136 OPERATION EXPLANATION OF COMPONENTS CALENDAR SETTING Adjust the date of the monitor. REMARK As long as “GPS Synchronization” menu is turned on, “Calendar” menu is not selectable. Select “Calendar” (b) on “Clock Adjustment” screen, then press switch F6. The “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display (A).
Page 137 EXPLANATION OF COMPONENTS OPERATION TIME SETTING Adjust the time of the monitor clock. REMARK As long as “GPS Synchronization” is turned on, “Time” menu is not selectable. Select “Time” (c) on “Clock Adjustment” screen, then press switch F6. The “Time” screen is displayed. When the hour display (D) is highlighted in yellow, operate the switches as follows to change hour display (D).
Page 138 OPERATION EXPLANATION OF COMPONENTS “12h/24h Mode” screen appears. F3: Moves to the next item (1 line below). Moves to the top line when it is on the bottom line. F4: Moves to the previous item (1 line above). Moves to the bottom line when it is on the top line.
Page 139 EXPLANATION OF COMPONENTS OPERATION LANGUAGE SETTINGS On “Language Setting” menu, it is possible to select the language used on the monitor display. The languages that can be selected are as follows. English, Japanese, French, Spanish, Portuguese, Italian, German, Swedish, Dutch, Danish, Norwegian, Fin- nish, Icelandic, Czech, Hungarian, Polish, Slovak, Slovene, Romanian, Croatian, Estonian, Latvian, Lithuanian, Bulgarian, Greek, Turkish, Serbian Select “Language”...
Page 140 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for 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”...
Page 141 EXPLANATION OF COMPONENTS OPERATION The “Operator ID Change” screen is displayed. • Input the already registered ID on the “Operator ID Change” screen and press F6. Then, the identified ID can be changed. A message is displayed below and the screen returns to the “Monitor Setting”...
Page 142 OPERATION EXPLANATION OF COMPONENTS WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is available without SKIP, the identified ID number is not displayed in the “Operator ID” column of “Monitor Setting” screen. Select “Operator ID” (6) on the “Monitor Setting” menu screen, then press switch F6 for 1 second.
Page 143 OPERATION MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this User Message menu (g). When there is any message, the User Message (1) at the top of the standard screen lights up.
Page 144 OPERATION EXPLANATION OF COMPONENTS CHECK MESSAGE On the standard screen, press switch F6. When there is any message, message display (1) lights While message display (1) is lit, press switch F6, and the mail confirmation menu (g) directly opens. Select the mail confirmation menu (g), and you can read the received message.
Page 145: Switches
EXPLANATION OF COMPONENTS OPERATION SWITCHES (1) Air conditioner switch (7) Engine shutdown secondary switch (2) Cigarette lighter (24 V) (8) Starting switch (3) Fuel control dial (9) Horn switch (4) Rear lamp switch (10) Room lamp switch (5) Headlamp switch (11) Wiper switch (6) Foot heater switch STARTING SWITCH...
Page 146 OPERATION EXPLANATION OF COMPONENTS FUEL CONTROL DIAL WARNING • When turning the fuel control dial to High idle (MAX) side while machine is stopped, check that the joystick (steering, directional and gear shift lever) is in NEUTRAL position. If the fuel control dial is turned to High idle (MAX) side while the joystick (steering, directional and gear shift lever) is in FORWARD or REVERSE position, the machine moves off suddenly and this may lead to serious per- sonal injury or death.
Page 147 EXPLANATION OF COMPONENTS OPERATION WIPER SWITCH The wiper switch operates the windshield wiper. The wiper switches are as follows. (A) LH: Left door (B) FF: Front window (C) RH: Right door (D) RR: Rear window (E) INT: Intermittent operation switch (for right and front doors) REMARK If the wiper blade is locked for some reason, the wiper stops automatically.
Page 148 OPERATION EXPLANATION OF COMPONENTS HORN SWITCH If you press the horn switch, the horn sounds. The horn switch is installed at the rear of the blade control lever on the right of the operator's seat. HEAD LAMP SWITCH The headlamp switch is used to light up the head lamp and monitor illumination.
Page 149 • Use the engine shutdown secondary switch only in an emergency. Immediately ask your Komatsu distributor for repair of the problem. • If this switch is set to the “STOP ENGINE” position by mistake while the machine is operating nor- mally, “Engine Shutdown Secondary SW In Operation”...
Page 150 OPERATION EXPLANATION OF COMPONENTS FOOT HEATER SWITCH Foot heater (a) is operated by foot heater switch. (A) LO position (B) Center position (C) HI position High The lamp inside the switch lights up by operating the switch. AIR CONDITIONER SWITCH Air conditioner switch is used to control the air conditioner.
Page 151: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION CONTROL LEVERS AND PEDALS (1) Work equipment lock lever (4) Decelerator/brake pedal (2) Parking brake lever (5) Blade control lever (3) Joystick (steering, directional and gear shift lever) BLADE CONTROL LEVER The blade control lever is used for lifting, tilting and angling of the blade. Lifting operation (A) RAISE Blade rises.
Page 152 OPERATION EXPLANATION OF COMPONENTS Tilting operation (E) LEFT tilt Blade tilts leftward. (B) HOLD Blade is stopped and held in this position. (F) RIGHT tilt Blade tilts rightward. Machine model Tilting amount ( mm { in} ) D61EX 435 {17.1} D61PX 515 {20.3} Angling operation Operate angle switch (L) forward and backward to angle the blade.
Page 153 EXPLANATION OF COMPONENTS OPERATION DECELERATOR/BRAKE PEDAL WARNING • When passing over the top of a hill or when dumping soil from a cliff, the load on the machine will suddenly be reduced and the travel speed will increase. This situation is dangerous. Depress the decelerator/brake pedal to lower the travel speed.
Page 154 OPERATION EXPLANATION OF COMPONENTS PARKING BRAKE LEVER WARNING • When leaving the operator's seat, set the parking brake lever securely to LOCK position (L) When the parking brake lever is not in LOCK position (L), if the joystick (steering, directional and gear shift lever) is touched by accident, it may lead to serious personal injury or death.
Page 155 EXPLANATION OF COMPONENTS OPERATION WORK EQUIPMENT LOCK LEVER WARNING • When standing up from the operator's seat, set the work equipment lock lever securely to LOCK po- sition (L). If the work equipment lock lever is not at LOCK position (L) and the blade control lever is touched by mistake, it may lead to serious accident.
Page 156 OPERATION EXPLANATION OF COMPONENTS JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) (PCCS LEV- Perform forward/reverse switching operation, steering opera- tion, and counter-rotation turn operation by using the joystick (steering, directional and gear shift lever). REMARK PCCS: Palm command control system (Electronic steering system) Forward/reverse switching operation (A) FORWARD...
Page 157 EXPLANATION OF COMPONENTS OPERATION Counter-rotation turn operation During steering operation, if lever is tilted further from the position where the operating effort becomes large, right and left tracks turn contrary direction to each other, and the machine makes counter-rotation turn. Gear shift operation The speed range is shifted by pressing switches (U) or (D) while the joystick (steering, directional and gear shift lever) is in...
Page 158: Other Equipment
OPERATION EXPLANATION OF COMPONENTS OTHER EQUIPMENT DOOR OPEN LOCK Use the door lock to fix the door in position after opening it. Push the door against the door catch (1). The door is fixed to the catch. To release the door, move lever (2) inside the cab to the front of the cab. The catch releases.
Page 159 EXPLANATION OF COMPONENTS OPERATION Insert the key as far as it will go to the shoulder (A) and turn it. If the key is turned when it is not inserted all the way to the end, it may break. CUP HOLDER This is for keeping a beverage can, cup, etc.
Page 160 OPERATION EXPLANATION OF COMPONENTS POWER SUPPLY OUTLET Power source inside cab 24V power supply NOTICE Do not use this as a power supply for 12V equipment. This will cause failure of the equipment. If cigarette lighter (1) is removed, its socket can be used as a power source.
Page 161 EXPLANATION OF COMPONENTS OPERATION FUSE NOTICE When replacing the fuse, be sure to turn the starting switch to OFF position and, after confirming that the system operating lamp is not lit, set the battery disconnect switch key to OFF position. •...
Page 162 OPERATION EXPLANATION OF COMPONENTS Fuse capacities and circuit names Fuse box (A) Fuse ca- Name of circuit pacity 30 A Front lamp and rear lamp 10 A Horn and preheater 15 A Foot heater 30 A Air conditioner 10 A Machine controller 1 15 A Air suspension seat and winch 30 A Cab power supply 1 30 A...
Page 163 EXPLANATION OF COMPONENTS OPERATION Fuse box (C) Fuse ca- Name of circuit pacity 10 A Radio 20 A Additional working lamp 20 A Cigarette lighter and 12 V socket 10 A Radio and lamp 10 A Front windshield wiper and rear windshield wiper 10 A R.H. and L.H. door windshield wipers FUSIBLE LINK NOTICE When replacing the fusible link, be sure to turn the starting switch to OFF position and, after confirming...
Page 164 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.
Page 165 EXPLANATION OF COMPONENTS OPERATION BATTERY DISCONNECT SWITCH CAUTION • Do not operate the battery disconnect switch while the engine is running. The large current generated by the alternator may burn the electric parts and cause a fire. When operating the battery disconnect switch, always stop the engine. •...
Page 166 • After the starting switch has been turned off, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. • While DEF system devices are operating, the system operating lamp lights up to return DEF to the tank.
Page 167 EXPLANATION OF COMPONENTS OPERATION RADIATOR GRILLE Open and close the radiator grille as needed in check and maintenance. METHOD FOR OPENING AND CLOSING RADIATOR GRILLE WARNING • Before opening and closing the radiator grille, stop the engine and check that the fan is stopped. If you touch the rotating fan, it will cause serious personal injury or death.
Page 168 OPERATION EXPLANATION OF COMPONENTS METHOD FOR CLOSING RADIATOR GRILLE NOTICE Radiator grille cannot be closed unless it is unlocked. If you try to close the radiator grille without un- locking, it may break. Lift up the radiator grille, and push lock releasing bar (2) to the direction of arrow.
Page 169 EXPLANATION OF COMPONENTS OPERATION HANDLE ID KEY (if equipped) The starting switch keys are ID keys which have built-in IC chips, and you can start the engine only with the usual keys (black) registered in the machine. ID KEY TYPES Usual key ID key used usually to start the engine (Black) (1)
Page 170 (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. 3-119...
Page 171 EXPLANATION OF COMPONENTS OPERATION PROCEDURES FOR CHECKING ID NUMBER OF REGISTERED NORMAL KEY (BLACK) Insert the usual key (black) in the starting switch and turn it to ON position. When the standard screen is displayed, press switch F6. Operate switches F1 and F2 to display “Monitor Setting” menu (A).
Page 172 OPERATION EXPLANATION OF COMPONENTS PROCEDURES FOR DELETING ID NUMBER OF REGISTERED NORMAL KEY (BLACK) After the “ID Key List” screen is displayed, select the ID No. of a usual key which you want to delete and hold down switch F6 for 2 seconds or more. The “Deletion of Regis- tered Key”...
Page 173 EXPLANATION OF COMPONENTS OPERATION PROCEDURES FOR DELETING ID NUMBERS OF ALL THE REGISTERED NOR- MAL KEYS (BLACK) You can delete the keys registered in the machine all together. Insert registration key (gray) in the starting switch and turn it to ON position (B) to display the “ID Key Setting” screen on the machine monitor.
Page 174 OPERATION EXPLANATION OF COMPONENTS PROCEDURES FOR REGISTERING ID NUMBER OF NEW NORMAL KEY (BLACK) Insert registration key (gray) in the starting switch and turn it to ON position (B) to display the “ID Key Setting” screen on the machine monitor. Replace the registration key with the normal key (black) to be registered and turn it to ON position (B).
Page 175 EXPLANATION OF COMPONENTS OPERATION REMARK If you again register a normal key (black) which 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.
Page 176 OPERATION EXPLANATION OF COMPONENTS HANDLE Komatsu Diesel Particulate Filter (KDPF) CAUTION • Exhaust gas temperature may increase higher than the previous models during the aftertreatment devices regeneration and the high temperature may last after the completion of regeneration. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt.
Page 177 “L04” lights up. In this case, the machine needs to be repaired by your Komatsu distributor. Also, the maximum engine output power and maximum engine speed are limited to protect the engine and KDPF system.
Page 178 • Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF fil- ters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
Page 179 EXPLANATION OF COMPONENTS OPERATION When the degree of emergency is low • If KDPF soot accumulation caution lamp (2) lights up in yellow (action level (3): “L01”), screen (A) is displayed first. • The action level goes out 2 seconds later, and the screen changes back to standard screen (B).
Page 180 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR MANUAL STATIONARY REGENERATION CAUTION Exhaust gas temperature may increase higher than the previous models during aftertreatment devices regenera- tion. Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being burnt. Also, keep combustible materials away from the exhaust pipe outlet and around the aftertreatment devices to prevent a fire.
Page 181 EXPLANATION OF COMPONENTS OPERATION REMARK After switch F6 is pressed in step 6., the screen shown in the figure may be displayed. This indicates that the opera- tions in steps 1 to 4 were not performed correctly or there is trouble other than KDPF soot accumulation abnormality. After checking that the engine is running normal, the park- ing brake lever and work equipment lock lever are in LOCK position (L) and the fuel control dial is set to Low...
Page 182 OPERATION EXPLANATION OF COMPONENTS The screen shown in the figure is displayed during the manual stationary regeneration. It may take more than 40 minutes to complete the manual stationary regeneration. Do not touch any switch on the screen or operate fuel control dial until the regeneration is completed and the standard screen appears again.
Page 183 EXPLANATION OF COMPONENTS OPERATION PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING If there is combustible material around the machine and the active regeneration that increases the exhaust tem- perature must not be performed, the automatic active aftertreatment devices regeneration can be disabled. Al- so, the regeneration in progress can be stopped.
Page 184 OPERATION EXPLANATION OF COMPONENTS REMARK • When the regeneration is disabled, aftertreatment devices regeneration disable pilot lamp (2) is lit on the standard screen. • The setting of regeneration disable is canceled by turning starting switch to OFF position. When the automatic regen- eration needs to be kept disabled, perform the above pro- cedure each time you start the engine.
Page 185 EXPLANATION OF COMPONENTS OPERATION Select “Regeneration Disable” and then press switch F6, and the regeneration stops. REMARK The regeneration performed to protect the system may not be stopped, but this is not a failure. PROCEDURE FOR CANCEL OF AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING CAUTION When canceling the regeneration disable, move the machine to a safe place and check that there is no...
Page 186 2000 hours. • If 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.
Page 187 40 hours after the first abnormality is fixed. The Komatsu’s Urea is composed of two major systems, which are the DEF system and the SCR catalyst Ass’y. DEF is supplied from DEF system into the exhaust system.
Page 188 OPERATION EXPLANATION OF COMPONENTS About the operation in cold weather DEF freezes at –11 °C {12.2 °F} . Urea SCR system is equipped with a heating system to thaw frozen DEF once it is frozen, for example, during parking and to prevent DEF from freezing during operation. In case DEF freezes during parking, once the engine starts running the heating system automatically starts pro- viding heat to thaw frozen DEF.
Page 189 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen displays the DEF level caution lamp (1), the DEF level gauge (2), information on the Urea SCR Sys- tem condition (3), and the current status of Inducement (4). If Inducement starts, stop the machine in a safe place and add DEF.
Page 190 OPERATION EXPLANATION OF COMPONENTS • Mild Inducement: The audible alert sounds in short and sharp beeps. 1 gradation of the DEF level gauge light up in red. The DEF level caution lamp (1) lights up in red. Action Level “L03” is displayed in red (5). Press F6 to display the “SCR Information”...
Page 191 Add DEF to the DEF tank immediately. In case the system does not come out of Inducement even if DEF is added in the tank, contact your Komatsu Distribu- tor. Inducement strategy when abnormalities are detected in the Urea SCR System...
Page 192 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen displays remaining time to the next Inducement status in the column (5), and information on the Urea SCR System condition (3), and the current status of In- ducement (4). • Warning: No audible alert. The DEF system caution lamp (1) lights up in yellow.
Page 193 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Mild Inducement”.
Page 194 “Final Inducement”, the engine speed is fixed to low idle. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 195 EXPLANATION OF COMPONENTS OPERATION If either the parking brake lever and work equipment lock lever are set to LOCK position or the joystick (steering, directional and gear shift lever) is in NEUTRAL position for over 3 sec- onds, “SCR Information” screen of the user menu will pop up automatically while the Urea SCR system is in Inducement.
Page 196 “Temporary Restoration from Inducement” in this man- ual. If Inducement advances to “Severe Inducement” and it becomes necessary to restore engine power, use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor.
Page 197 EXPLANATION OF COMPONENTS OPERATION • Final Inducement: The audible alert sounds in continuous beep. The KDPF system caution lamp (1) lights up in red. The DEF system caution lamp (2) lights up in red. Action level “L04” lights up in red (3) at action level display. Press F6 to display the “SCR Information”...
Page 198 OPERATION EXPLANATION OF COMPONENTS Press F6 to display the menu windows popping up in the bottom half of the “SCR Information”. The menu windows popping up in the bottom half of the “SCR Information” screen alternate every 15 seconds as shown in the graphics A and B.
Page 199 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 Komatsu distributor. The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not cor- rected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final Inducement”...
Page 200 2000 hours. • If the machine is operated without DEF filter attached, or with the filter other than Komatsu 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.
Page 201 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.
Page 202: Machine Operations And Controls
Clean DEF line and check it for leakage. Check around DEF tank for dirt, and clean the blue DEF filler cap and the area around. Check DEF tank, pump, injector, hoses, and joints for leakage. If any problem is found, ask your Komatsu distributor for re- pair.
Page 203 11. Check the seat belt and mounting hardware. Check the seat belt and mounting hardware for any abnormality. If any damage is found, ask your Komatsu distributor to replace it with new one. 12. Check and clean the camera.
Page 204 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING BEFORE STARTING Always check the items in this section before starting the engine each day. METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK Perform this procedure before operating the machine. Prepare a container to catch drained fuel. Open the fuel tank inspection cover on the right side of the machine.
Page 205 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 206 OPERATION MACHINE OPERATIONS AND CONTROLS • When the oil level is below L mark The oil is insufficient. Add hydraulic oil through oil filler port (F) on top of the hydraulic tank. REMARK The oil level changes depending on the oil tempera- ture.
Page 207 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT WARNING • Do not open the radiator cap unless necessary. When checking the coolant level, check the reser- voir tank when the engine is cold. • Do not remove the reservoir tank cap while the radiator coolant temperature is high. Boiling coolant may spurt out.
Page 208 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Wait for the temperature to go down, and then start the work. Check the oil level either before engine starts or at least 15 minutes after the engine stops.
Page 209 MACHINE OPERATIONS AND CONTROLS OPERATION Take the end of hose (2) out of the inspection window. Loosen drain plug (P) to drain excess oil. When draining the engine oil, put a container to catch the oil under hose (2). Check the oil level again. After the oil is adjusted to a proper level, insert dipstick (G) fully into the dipstick pipe again.
Page 210 • If fuses are frequently blown or if there are traces of short-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.
Page 211 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING FUEL LEVEL, ADDING FUEL WARNING When adding fuel, never spill the fuel or let it overflow. This may cause fire. If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand.
Page 212 OPERATION MACHINE OPERATIONS AND CONTROLS After checking, turn the starting switch back to OFF posi- tion (A). 3-161...
Page 213 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the alarm buzzer sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and inspection. DEF injector and/or DEF pump may need to be replaced.
Page 214 OPERATION MACHINE OPERATIONS AND CONTROLS Check the DEF level gauge on the machine monitor. After checking, turn the starting switch back to OFF posi- tion (A). Check that the engine is stopped. If DEF is insufficient, add it. Open DEF tank filler port cover (1). For the opening and closing method of the cover, see “METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT COVER”.
Page 215 MACHINE OPERATIONS AND CONTROLS OPERATION 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 °. REMARK • It is recommended to use a nozzle having a diameter and a length specified by ISO 22241-4 and an auto stop function to add DEF.
Page 216 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADDING DEF FROM BIB CONTAINER CAUTION • When opening or closing the DEF tank filler port cover, place the machine on a level ground, lower the work equipment to the ground, stop the engine, and then perform the operation. •...
Page 217 MACHINE OPERATIONS AND CONTROLS OPERATION Check the positions of (a) to (d) shown in the figure. Put the BIB container gently on it. Turn the DEF tank filler port cap (2) counterclockwise (O) and open it. Direction of (O): Open Direction of (C): Close Insert the bellows hose of the BIB container into filler port (2).
Page 218 OPERATION MACHINE OPERATIONS AND CONTROLS 10. While watching sight gauge (3), add DEF through filler port (2) until float (4) reaches line F (5). Line (6) in the sight gauge indicates approximately 5 ℓ {1.32 U.S.Gal} below line F, and line (7) indicates approxi- mately 10 ℓ {2.64 U.S.Gal} ...
Page 219 If the lamps do not light up, a broken bulb or disconnected wire are the possible causes. Ask your Komatsu distributor for repairs. After finishing the check, turn the head lamp to OFF posi- tion (c) and turn the rear lamp to OFF position (e).
Page 220 2 sec- onds. If they do not light up, the machine monitor may be defective or 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.
Page 221 MACHINE OPERATIONS AND CONTROLS OPERATION Return the starting switch back to OFF position (A). 3-170...
Page 222 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING BACKUP ALARM OPERATION STATUS Turn the starting switch to ON position (B). Set the parking brake lever to LOCK position (L). Set the joystick (steering, directional and gear shift lever) in REVERSE position (R). The alarm must sound immediately at this time.
Page 223 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR'S SEAT WARNING • When adjusting the position of the operator's seat, always set the work equipment lock lever and parking brake lever to LOCK positions to prevent any accidental contact with the control levers. •...
Page 224 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TILTING SEAT Pull up the tilt adjustment lever and adjust the front angle of the seat. • To raise the front of the seat, apply your weight to the rear of the seat, while pulling up lever. •...
Page 225 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING LUMBER SUPPORT Turn the adjustment knob to the right or left, and give proper tension to the waist part. The back cushion tension is increased by turning the adjust- ment knob to the right. The tension of the back cushion can be adjusted to 5 steps.
Page 226 OPERATION MACHINE OPERATIONS AND CONTROLS MECHANICAL SUSPENSION SEAT (if equipped) METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION 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) After adjusting, release the lever. METHOD FOR RECLINING SEAT The reclining of the seat becomes large when the seat is moved forward, and it becomes smaller as the seat is moved backward.
Page 227 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING WEIGHT AND HEIGHT OF SEAT Pull out the crank of knob (1) under the seat and turn it so that weight indicator (2) reads the green range. You can adjust the height by turning knob (1) in the green range. X: When crank is stored Y: When crank is pulled out (for adjusting weight) Adjust the weight according to the following procedure.
Page 228 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING LUMBER SUPPORT Turn the adjustment knob to the right or left, and give proper tension to the waist part. The back cushion tension is increased by turning the adjust- ment knob to the right. The tension of the back cushion can be adjusted to 5 steps.
Page 229 MACHINE OPERATIONS AND CONTROLS OPERATION AIR SUSPENSION SEAT (HIGH-BACK SEAT) (if equipped) METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION Pull up the fore-aft adjustment lever, and set the seat to the desired position. Fore-and-aft adjustment range: 210 mm {8.3 in} (21 steps) After adjusting, release the lever. METHOD FOR RECLINING SEAT The reclining of the seat becomes large when the seat is moved forward, and it becomes smaller as the seat is moved backward.
Page 230 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING WEIGHT ON SEAT When adjusting the seat cushion, turn the starting switch to ON position since the air compressor built in the seat is used for the adjustment. NOTICE Avoid using the height adjustment lever continuously for 1 minute or longer since such practice can damage the air compressor.
Page 231 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING SEAT CUSHION IN FORE-AFTER DIRECTION Pull up the seat cushion fore-aft adjustment lever, and set the seat cushion to the desired position. Fore-aft adjustment range: 60 mm {2.4 in} After adjusting, release the lever. METHOD FOR ADJUSTING LUMBER SUPPORT Adjust the lumber support while keeping the staring switch in ON position.
Page 232 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING MIRRORS WARNING Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot secure the visibility and may be injured or may lead to a serious personal injury or death. Adjust the mirror by moving it.
Page 233 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
Page 234 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR UNFASTENING SEAT BELT Press button (2) in buckle (1) and remove tongue (3) from buckle (1). Hold grip (4) and slowly return the belt into retractable de- vice (5). The belt retracts automatically. 3-183...
Page 235 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING • When starting the engine, check and make sure park- ing brake lever (1) and work equipment lock lever (4) are secured in LOCK position. If the blade control lever is touched by accident when starting the engine, the blade may move unexpectedly, and this may lead to a serious injury or death.
Page 236 OPERATION MACHINE OPERATIONS AND CONTROLS If joystick (steering, directional and gear shift lever) (2) is in F or R, the letter “P” on speed range display will flash. Lower the blade to the ground. Check that blade control lever (3) is in HOLD position (b). Check that work equipment lock lever (4) is in LOCK posi- tion (L).
Page 237 If a password is set, the input display screen will be indi- cated on the machine monitor. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the password. 10. Perform the following inspection on the machine monitor.
Page 238 OPERATION MACHINE OPERATIONS AND CONTROLS If the caution lamp (14) stays lit, immediately check the lit item. For details of contents and check methods for caution lamp, see “CAUTION LAMP LIST”. 11. When the maintenance time caution lamp (15) is lit, press switch F6 to check the item, and perform the maintenance immediately.
Page 239: Method For Starting Engine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING ENGINE METHOD FOR STARTING ENGINE IN NORMAL WEATHER WARNING • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a fire or serious personal injury or death.
Page 240 OPERATION MACHINE OPERATIONS AND CONTROLS When the engine starts, release the starting switch key (2). The key will return automatically to ON position (B). REMARK • White smoke may be discharged 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.
Page 241 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING ENGINE IN COLD WEATHER WARNING • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may cause a fire or serious personal injury or death.
Page 242 OPERATION MACHINE OPERATIONS AND CONTROLS Check if preheating pilot lamp (3) on the machine monitor is lit. Leave this condition until preheating pilot lamp (3) goes out. The lighting time of preheating pilot lamp (3) varies with the ambient temperature as shown in the table. Ambient temperature Lighting time (sec.) ( °C { °F} )
Page 243 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • Regardless of the ambient temperature, if the starting switch (2) is turned counterclockwise from OFF posi- tion, preheating pilot lamp (3) lights up and preheating starts. (Pre-heating continues while the starting switch (2) is held at the left.) For the details of the preheat time, see the table in step 5.
Page 244: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 245 METHOD FOR RUNNING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Page 246 • (C) to (D): White range Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. METHOD FOR ENGINE WARM-UP OPERATION IN COLD SEASON This machine is warmed up automatically by the automatic warm-up operation system.
Page 247 11. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. After warm-up operation, run he engine at medium speed and slowly drive forward and reverse so that the whole equipment becomes uniform temperature.
Page 248: Method For Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STOPPING ENGINE WARNING Keep away from the exhaust pipe immediately after stopping the engine. NOTICE • If the engine is abruptly stopped before it has cooled down, service life of the engine parts may be reduced. Do not stop the engine abruptly except in an emergen- If the engine overheats, do not stop it suddenly.
Page 249 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • When engine starting switch (2) is turned to OFF posi- tion, the engine stops, but the machine's main power supply is not turned off immediately. During this period, the power is supplied to the con- troller to save the operating condition and then finish the system.
Page 250: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE METHOD FOR MOVING MACHINE WARNING • Before moving the machine off, check that the area around the machine is safe, then sound the horn be- fore starting.
Page 251 MACHINE OPERATIONS AND CONTROLS OPERATION Set work equipment lock lever (6) to FREE position (F). Set blade control lever (7) to RAISE position (R) and raise the blade to 40 to 50 cm {15.7 to 19.7 in} above the ground. Depress the decelerator/brake pedal. Set the joystick (steering, directional and gear shift lever) (4) to FORWARD position (F) or REVERSE position (R).
Page 252 OPERATION MACHINE OPERATIONS AND CONTROLS Make the machine move off by releasing 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. 3-201...
Page 253 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STOPPING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, place parking brake lever (1) in LOCK position and insert blocks underneath the track shoes to pre- vent the machine from moving.
Page 254: Shift Gears
OPERATION MACHINE OPERATIONS AND CONTROLS SHIFT GEARS Speed range can be changed while traveling, it is not necessary to stop the machine for gear shifting. Select a desired speed range by depressing UP switch or DOWN switch of joystick (steering, directional and gear shift lever) (1).
Page 255 MACHINE OPERATIONS AND CONTROLS OPERATION QUICK SHIFT MODE • Press UP switch (U) of the joystick (steering, directional and gear shift lever) once, and speed range changes 1st → 2nd and 2nd → 3rd. • Press DOWN switch (D) of the joystick (steering, direction- al and gear shift lever) once, and speed range changes 3rd →...
Page 256 OPERATION MACHINE OPERATIONS AND CONTROLS VARIABLE SHIFT MODE • Each time UP switch (U) on the joystick (steering, direc- tional and gear shift lever) is pressed, upper bar graph lights up by 2 segments and travel speed is increased by approximately 0.4 km/h {0.2 MPH} .
Page 257 MACHINE OPERATIONS AND CONTROLS OPERATION REVERSE TRAVEL SPEED SETTINGS Reverse travel speed can be set by selecting the ratio of reverse travel speed against forward travel speed out of the following 5 levels. “-1”: Approximately 20 % slower than forward travel speed. “0”: Same as forward travel speed.
Page 258: Method For Switching Between Forward And 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 distributor for repair. Release decelerator/brake pedal (1) and raise the engine speed.
Page 259: Method For Steering Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STEERING MACHINE WARNING • Avoid turning on a slope whenever possible, since sideways slip occurs easily. Take care particularly on soft ground or clay land. • Do not make a pivot turn at a high speed. METHOD FOR NORMAL TURNING OPERATION During travel, tilt joystick (steering, directional and gear shift lever) (1) in a direction you want to turn.
Page 260 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR COUNTER-ROTATION TURN NOTICE • Before performing a counter-rotation turn, check the safety around the machine. • When performing a counter-rotation turn, if the load is not equal on the left and right sides, the ma- chine may perform a pivot turn, so check the ground conditions and be careful not to hit any obsta- cles.
Page 261 MACHINE OPERATIONS AND CONTROLS OPERATION To make counter-rotation turn to the left, tilt the joystick (steering, directional and gear shift lever) forward and tilt it to left (L), and tilt it fully further from the point where the joystick operating effort becomes large. The R.H.
Page 262 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TURNING WHILE TRAVELING ON DOWNHILL METHOD FOR TURNING THE MACHINE GRADUALLY WHILE TRAVELING FOR- WARD 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.
Page 263: Recommended Working Modes For Works
MACHINE OPERATIONS AND CONTROLS OPERATION RECOMMENDED WORKING MODES FOR WORKS FEATURES OF WORKING MODES Gear shift mode Gear shift mode can be changed with gear shift mode selector switch (1). Gear shift mode Features Travel speed is set to suit the general work load and gear shifting is easy. This is ef- Quick shift fective for the operator who is accustomed to 3 speeds gear shifting pattern or for the work which requires frequent gear shifting.
Page 264 OPERATION MACHINE OPERATIONS AND CONTROLS Steering mode Steering mode can be changed on the Mode Select screen. Steering mode Features When lever is tilted to the point where the lever operating effort becomes heavy, the inside track of turning machine stops and the machine starts pivot turn. When lever is NORMAL tilted further, stopped track starts rotating in reverse and the machine starts counter- rotation turn.
Page 265 MACHINE OPERATIONS AND CONTROLS OPERATION RECOMMENDED WORKING MODES Operating mode Type of operation Soil quality Operating conditions Heavy-duty operations, high productivity Normal soil ○ ○ desired Digging, hauling Sand, soft soil Light-duty operations, easily slips ○ Uneven ground, Load changes easily ○...
Page 266: Precautions For Operation
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR OPERATION WATCH GAUGES If the hydraulic oil temperature caution lamp lights up during operation, reduce the load and wait for the temper- ature to go down. PERMISSIBLE WATER DEPTH When operating in water, always keep the bottom of carrier roll- ers (1) above the surface of the water.
Page 267: Precautions When Operating On Slope
MACHINE OPERATIONS AND CONTROLS OPERATION PRECAUTIONS WHEN OPERATING ON SLOPE Pay attention to fuel level If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle of the machine or the swaying of the machine. This makes the engine stop, so be careful not to let the fuel level in the fuel tank become too low.
Page 268: Precautions For Blind Spots Caused By Cab And Rops Structures
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUC- TURES WARNING The cab stays create blind spots. When operating, check carefully that there is no person or obstacle in the surrounding area. RECOMMENDED APPLICATIONS In addition to the following, it is possible to further increase the range of applications by using various attach- ments.
Page 269 MACHINE OPERATIONS AND CONTROLS OPERATION WORKS OF CUTTING AND DITCHING HARD OR FROZEN GROUND For digging and ditch excavation of hard or frozen ground, tilt the blade. Even hard ground can be dug effectively by a tilted or angled blade. WORKS OF FELLING TREES AND REMOVING STUMPS NOTICE Do not perform stump removal or other hard work by angling tilting the blade.
Page 270: Method For Adjusting Work Equipment
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING WORK EQUIPMENT For adjusting the play of center ball, see “METHOD FOR ADJUSTING SHIMS AT CENTER BALL”. METHOD FOR ADJUSTING ANGLE OF BLADE EDGE WARNING It is dangerous if the work equipment moves by mistake when the blade edge angle is adjusted. Set the work equipment in a stable condition, then stop the engine.
Page 271 MACHINE OPERATIONS AND CONTROLS OPERATION Blade Distance be- edge an- Method tween joints (B) gle (A) Install the cover (3) inside out. Set grease fitting (4) to the position Lengthen than Increas- of V-shape groove (5) on the cover the standard (3).
Page 272: Tips For Longer Undercarriage Life
OPERATION METHOD • Use a track shoe suitable for soil condition. For selection of the shoe, consult your Komatsu distributor. • Do not let the shoe slip during operation. If the shoe starts slipping, decrease the load to prevent slipping.
Page 273 Frequent inspection and prompt repair will reduce repair costs. The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per- form periodical inspection and contact the Komatsu distributor in your area when machine has approached re- pairable limits and reversing limits.
Page 274: Method For Parking Machine
OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR PARKING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Place the machine on a firm, level ground. Do not park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, place parking brake lever (3) in LOCK position and insert blocks underneath the track shoes to pre- vent the machine from moving.
Page 275: Method For Checking After Finishing Work
If oil or coolant leakage or any abnormality is detected, repair it. Check DEF tank, pump, injector, hose, and joint for leakage. If any abnormality is found, ask your Komatsu distributor for repair. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
Page 276: Lock
OPERATION MACHINE OPERATIONS AND CONTROLS LOCK The following sections are lockable to prevent vandalism. Places that can be locked with the starting switch key. • Cab door opener (1) (right and left) • Engine side cover (2) (left) • Hydraulic tank inspection cover (3) •...
Page 277 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING CAP WITH LOCK PROCEDURE FOR OPENING CAP WITH LOCK Insert the key into the key slot. Make sure that you have inserted the key fully (1) before turning it. If the key is turned when only partially inserted, it may break.
Page 278 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP PROCEDURES FOR OPENING FUEL FILLER PORT CAP Raise lever (1) in the direction (a). Turn lever (1) in direction (c) (counterclockwise) approxi- mately 35 °. The cap stops at the stopper, and you can open it. PROCEDURES FOR CLOSING FUEL FILLER PORT CAP After turning lever (1) in the (c) direction (counterclock- wise), keep it in that position and fit the cap.
Page 279 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR OPENING AND CLOSING COVER WITH LOCK METHOD FOR OPENING COVER WITH LOCK Insert the key into the key slot. Turn the key counterclockwise and open the cover by pulling the cover handle. • Cab door opener Position (A): OPEN Position (B): CLOSE (LOCK)
Page 280 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT COVER CAUTION • When opening or closing the DEF tank filler port cover, place the machine on a level ground, lower the work equipment to the ground, stop the engine, and then perform the operation. •...
Page 281: Handle Air Conditioner
HANDLE AIR CONDITIONER OPERATION HANDLE AIR CONDITIONER Ventilation while cooling • When running the air conditioner for a long time, turn the lever to FRESH position once an hour to perform ventilation and cooling. • If you smoke when the air conditioner is on, the smoke may hurt your eyes. In such case, open the window and turn the lever to FRESH for a while for ventilation and driving smoke out.
Page 282: Method For Operating To Prevent Dust From Entering Into Cab
OPERATION HANDLE AIR CONDITIONER BLOWER CHANGEOVER SWITCH Blower selector switch is used to control the air flow at cooling and heating, and also used as a main switch. • It changes the air flow in 4 levels of 1 (low) → 2 → 3 → 4 (high).
Page 283: Method For Replacing Receiver
If the receiver is used with desiccating agent of which absorbing limit 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. 3-232...
Page 284: Handle Radio
OPERATION HANDLE RADIO HANDLE RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them. •...
Page 285 HANDLE RADIO OPERATION DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display. Each time you press this button, frequency, clock and band are shown on the display in this order. If 1.5 seconds passes while a band is shown, a frequency will be displayed. As long as AUX is selected, this button alternately switches the display between AUX and the clock.
Page 286 OPERATION HANDLE RADIO NOTICE • A stereo miniature plug can be connected. Read the instruction manual of the equipment to connect carefully. • As a power source for the equipment to connect, use the battery attached to that equipment. If you use an electric power supply installed to the machine, the noise may occur. •...
Page 287: Method For Controlling Radio
HANDLE RADIO OPERATION METHOD FOR CONTROLLING RADIO METHOD FOR ADJUSTING FREQUENCY Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency. Press the △ button, and the frequency increases; • press the ▽...
Page 288 OPERATION HANDLE RADIO METHOD FOR REGISTERING PRESET Hold down one of 1 to 6 of preset button (1) while listening to the radio. The currently received frequency is registered to the preset number corresponding to the pressed button. “Example” While a frequency is displayed, keep pressing button 1 of preset button (1), and the preset number “P-1” is dis- played.
Page 289: Antenna
HANDLE RADIO OPERATION METHOD FOR ADJUSTING LOW REGISTER RANGE (BASS) Press sound control button (1) to light up “BAS” on the dis- play. You can adjust the low register range (bass) of the sound. Press tuning/time adjustment button (2) to adjust the low register range (bass).
Page 290: Transportation
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 to the figure, decide whether the blade should be re- moved for transportation.
Page 291: Loading And Unloading With Trailer
TRANSPORTATION OPERATION LOADING AND UNLOADING WITH TRAILER WARNING • Since loading and unloading of the machine is dangerous, be extremely careful. • When loading or unloading the machine, lower the engine speed, set the speed range to the 1st, and operate slowly.
Page 292 OPERATION TRANSPORTATION Place the parking brake lever in FREE position (F). Set the speed range to 1st or less in variable mode. Set the travel direction toward the ramps and drive slowly. The center of gravity of the machine shifts suddenly at the joint between the ramps and the trailer, and the machine is unbalanced and becomes unstable.
Page 293 TRANSPORTATION OPERATION • (A): Wind chains or wire ropes around the track shoe. • (B): Pass chains or wire ropes through the holes of track links. Place wire rope protection pads on the corners of the machine. PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm and level ground.
Page 294: Method For Lifting Machine
This lifting method applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. When lifting the machine, stop it on a level place, then lift it as follows.
Page 295 TRANSPORTATION OPERATION Select the lifting tool such as wire ropes and slings match- ing to the weight of the machine, and fit the wire ropes to the slinging position. (A) Mark indicating slinging position NOTICE • Use protectors, etc. so that the wire ropes will not be broken at sharp edges or narrow places.
Page 296: Cold Weather Operation
When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, contact your Komatsu distributor 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.
Page 297 COLD WEATHER OPERATION OPERATION BATTERY WARNING • Do not bring any open flame near the battery. Otherwise, it may explode since the battery generates the flammable gas. • Battery electrolyte is dangerous object. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 298: Precautions After Daily Work Completion
FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. • If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by re- peated freeze, ask your Komatsu distributor to inspect. 3-247...
Page 299: Precautions For Long-Term Storage
PRECAUTIONS FOR LONG-TERM STORAGE OPERATION PRECAUTIONS FOR LONG-TERM STORAGE PREPARATION FOR LONG-TERM STORAGE When putting the machine in long-term storage (more than one month), store it as follows. • Clean and wash all parts of the machine and store it indoors. If the machine has to be stored outdoors, place it on a level ground and cover it with tarpaulins.
Page 300: Starting Machine After Long-Term Storage
If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement. Dispose of drained DEF according to the local regulations and rules.
Page 301: Troubles And Actions
If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic sys- tem, the brake works and the machine cannot move. To move the machine in this case, the oil pressure in the brake circuit must be heightened to the specified level with a special device. Contact your Komatsu dis- tributor.
Page 302: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS • If the machine gets stuck in the mud or a heavy thing needs to be towed, install a towing wire rope to the draw bar pin. Connect a wire rope to the part indicated with the arrow in the drawing.
Page 303 TROUBLES AND ACTIONS OPERATION METHOD FOR REMOVING AND INSTALLING BATTERY Open hydraulic tank inspection cover (1). Turn the battery disconnect switch to OFF position (O). Remove nuts (A) and (B) (4 places each) of mounting fix- ture for battery. Loosen the terminal nut and disconnect the cable from the battery.
Page 304 OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, it is dangerous that the battery may explode. Al- ways follow the instruction manual accompanying the charger, and observe the following. •...
Page 305 TROUBLES AND ACTIONS OPERATION START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 306 OPERATION TROUBLES AND ACTIONS PROCEDURE FOR CONNECTING JUMPER CABLE Turn the starting switch and battery disconnect switch of the failed machine, and the starting switch of the nor- mal machine to OFF position. Connect the clip of jumper cable (A) to the positive (+) ter- minal of battery (C) on the failed machine.
Page 307: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 308 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Charge level caution lamp does not Defective monitor Replace. (*) light up when engine is stopped. Defective wiring Check, repair. (*) (Starting switch is at ON position.) Outside of electrical heater is not Defective wiring Check, repair.
Page 309 PHENOMENA AND ACTIONS FOR CHASSIS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 310 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Hydraulic oil gets overheat. (Pointer Work load is too high. Lighten the work load to prevent trav- is in red range.) el relief. Work equipment is relieved. Avoid operating the blade to the stroke end of cylinder.
Page 311 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • As for the corrective actions indicated with (*) in the remedy column, contact your Komatsu distributor. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below.
Page 312 (3) for the point of contact is displayed in the message column at the bottom of the screen. REMARK If no point of contact telephone number is registered, no tele- phone number is displayed. Ask your Komatsu distributor for the telephone number regis- tration if necessary. 3-261...
Page 314: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 315: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 316: Precautions For Scr Assembly
MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR SCR ASSEMBLY Be careful for the high temperature parts when performing inspection and maintenance. Even after the engine stops the parts around SCR device may be at high temperature. DUSTY JOBSITES When working at dusty jobsites, observe the following. •...
Page 317: Checks After Inspection And Maintenance
PRECAUTIONS FOR MAINTENANCE MAINTENANCE CHECKS AFTER INSPECTION AND MAINTENANCE If you forget to perform the inspection and maintenance, unexpected problems may occur, and this may lead to personal injury. Always observe the following. Checks after operation (with engine stopped) • Have any inspection and maintenance points been forgotten? •...
Page 318: Outline Of Maintenance
When shipped from the plant, Engine oil EO10W30–DH is used. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the en- gine such as deteriorated oil may reduce lubricating function, and it may cause failure, shortening of the machine life, lowering of performance and increase of fuel consumption.
Page 319 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.
Page 320 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 321 Make sure that the oil is well mixed before sampling. • Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor.
Page 322 • When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, consult your Komatsu distributor. • Do not open packages of spare filters until just before they are to be used.
Page 323: Handle Electrical Components
Never install any electrical components other than those specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. •...
Page 324: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 325 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE Tighten the hoses to the torque shown in the table. Width Tightening torque acros Nominal - No. of Target value Allowable range s flats threads "a" "b" Nm kgm lbft Nm kgm lbft (mm) 9/16-18UNF...
Page 326: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE 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”.
Page 327: Maintenance Interval When Diesel Fuel Mixed With Bio-Fuel Is Used
MAINTENANCE SCHEDULE TABLE MAINTENANCE METHOD FOR CHANGING OIL IN HYDRAULIC TANK, REPLACING HYDRAULIC OIL FILTER ELEMENT, REPLACING HST OIL FILTER CARTRIDGE, AND CLEANING HYDRAULIC TANK STRAINER..4-65 METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA- TOR (FOR CONTROL CIRCUIT) ......................4-69 METHOD FOR CHECKING ALTERNATOR ....................
Page 328: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING • If inspection, cleaning, or maintenance is performed while the engine is running, dust enters into the engine and damages it. Be sure to stop the engine before performing these works. •...
Page 329 MAINTENANCE PROCEDURE MAINTENANCE • When the inside yellow piston of dust indicator (1) laps over the peripheral red zone (A) METHOD FOR CLEANING AND REPLACING OUTER ELEMENT Open the engine side cover on the left side of the machine. Remove clips (2) (4 pieces) and remove cover (3). NOTICE •...
Page 330 MAINTENANCE MAINTENANCE PROCEDURE Blow dry compressed air (Max. 0.2 MPa {2.1 kg/cm 30.0 PSI}) from the inside of the outer element along the pleats. Blow dry compressed air from the outside of the outer ele- ment along the pleats. Blow dry compressed air again from the inside of the outer element along the pleats.
Page 331 MAINTENANCE PROCEDURE MAINTENANCE REMARK • Immediately after a new element has been installed, the yellow piston of the dust indicator may go to the position between 3.7 to 5.0 kPa {0.04 to 0.05 kg/cm , 0.57 to 0.71 PSI}, but this does not indicate any abnormality.
Page 332 MAINTENANCE MAINTENANCE PROCEDURE Replace O-ring (7) of cover (3) with a new one. Set the arrow mark on cover (3) at the top, install to the air cleaner body, then secure with clip (2). Push the button of dust indicator (1). The yellow piston returns.
Page 333: Method For Cleaning Inside Of Cooling System
NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 334 MAINTENANCE MAINTENANCE PROCEDURE Place the machine on a level place. Stop the engine. Turn radiator cap (1) slowly until it hits the stopper and re- lease the pressure. While pushing radiator cap (1), turn it until it touches to the stopper, then remove it.
Page 335 MAINTENANCE PROCEDURE MAINTENANCE 11. Stop the engine. 12. Open drain valve (3) to drain the coolant. 13. Close drain valve (3). 14. Add Non-Amine Engine Coolant (AF-NAC) through the coolant filler port up to the mouth of the port. For the density of Non-Amine Engine Coolant (AF-NAC) , see “Coolant density table”. 15.
Page 336: Method For Cleaning Inside Machine
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING INSIDE MACHINE 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 equipment such as protective eyeglasses and dust mask.
Page 337: Method For Checking And Adjusting Track Tension
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- cedure, ask your Komatsu distributor for repair. METHOD FOR INCREASING TRACK TENSION NOTICE •...
Page 338 METHOD FOR DECREASING TRACK TENSION WARNING It is extremely dangerous to release the grease by any method other than the 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.
Page 339: Method For Checking Looseness And Tightening Track Shoe Bolts
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE BOLTS NOTICE If the machine is used with track shoe bolts loose, they will break. Tighten any loose bolt immediately. Check for looseness of track shoe bolt (1). If any bolt is loose, retighten it. METHOD FOR TIGHTENING TRACK SHOE BOLTS Tighten the track shoe bolts in the order shown in the fig- ure.
Page 340: Method For Checking Idler Oil Level
When oil oozes out through thread portion You do not need to add oil. • When no oil oozes out through thread portion The oil is insufficient. Ask your Komatsu distributor for adding. After checking, tighten plug (1). METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE Since the idlers are forced to move forward and backward by an external force, guide plates will be worn out.
Page 341: Method For Inverting And Replacing Cutting Edge And End Bit
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR INVERTING AND REPLACING CUTTING EDGE AND END BIT WARNING It is dangerous if the work equipment moves by mistake when the cutting edge and end bit are turned 180 deg. or replaced. Set the work equipment in a stable condition, place the work equipment lock lever in LOCK position, then stop the engine.
Page 342: Clean And Check Radiator Fins And Oil Cooler Fins
MAINTENANCE MAINTENANCE PROCEDURE CLEAN AND CHECK RADIATOR FINS AND OIL COOLER FINS If there is any mud or dirt stuck to the radiator or oil cooler, clean them. Check the rubber hoses. If they are cracked or fragile, replace them. Also, check the hose clamp for looseness. METHOD FOR CLEANING FIN BY ROTATING HYDRAULIC DRIVE FAN IN RE- VERSE NOTICE...
Page 343 MAINTENANCE PROCEDURE MAINTENANCE Open engine side cover (6). Remove front cover (7) and engine side covers (8) and (9). Open hydraulic tank inspection cover (10). Open fuel tank inspection cover (11). Turn starting switch (1) to ON position. With the user menu on the machine monitor, set “Machine Setting”...
Page 344 MAINTENANCE MAINTENANCE PROCEDURE REMARK • If dirt is caught in the radiator fins, blow with compressed air to clean. • Check that there is no dirt sticking to the KDPF or turbocharger. • In a cold circumstance, perform the cleaning by Fan Reverse Mode within less than 5 minutes. If the fan reverse rotation is performed for a long time, the DEF hose may freeze.
Page 345 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CLEANING RADIATOR FIN WARNING • If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the compressed air, high-pressure water, or steam, there is a danger of personal injury. Always wear protective equipment such as protective eyeglasses and dust mask.
Page 346: Method For Cleaning Hydraulic Tank Breather
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING HYDRAULIC TANK BREATHER At the check and maintenance, if the breather is dirty, clean it. Remove nut (2) of breather assembly (1) on the top of the hydraulic tank. Use a tool when the nuts are so tight to remove. Remove cover (3).
Page 347: Method For Replacing Door Damper
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING DOOR DAMPER Measure groove depth (A) of door damper rubber (1). When groove depth (A) decreases to 2 mm {0.079 in} or less, replace the damper. The damper is installed at top and bottom, 2 pieces each on the R.H.
Page 348: Method For Checking Door Lock Striker
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING DOOR LOCK STRIKER Measure wear (A) of the door lock striker. If wear (A) is 0.5 mm {0.02 in} or more, replace the door lock striker. If you use it as it is, its play increases and can cause breakage of the hinge and lock door.
Page 349: Method For Checking Wiper Blade
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING WIPER BLADE (1) Front wiper (4) Wiper arm (2) Rear wiper (5) Wiper blade (3) Door wiper Check each wiper visually, and replace the wiper blade in the following cases. • When wiping is uneven •...
Page 350 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING REAR WIPER The rear wiper is hooked at portion (A). Move the blade in the direction of the arrow. The blade comes off. Install the new blade and hook it securely. METHOD FOR REPLACING DOOR WIPER The front wiper is hooked at portion (A).
Page 351: Method For Checking And Maintenance Air Conditioner
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER METHOD FOR CHECKING LEVEL OF REFRIGERANT (GAS) WARNING • Be sure to handle the refrigerant (gas) according to the local regulations. • If the refrigerant used in the air conditioner gets into your eyes or is splashed on your hands, it may cause loss of sight or frostbite.
Page 352: Method For Bleeding Air From Hydraulic Circuit
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT Bleed air from the circuit after the filter element or strainer, etc. has been replaced or cleaned. Since the engine must be started and the blade must be operated, see OPERATION. Bleed air from the pump according to the following procedure.
Page 353: Method For Releasing Pressure In Hydraulic Circuit
METHOD FOR CHECKING ELECTRICAL INTAKE AIR HEATER Check before starting in the cold weather (once a year). Ask your Komatsu distributor for check of the electrical intake air heater. 4-40...
Page 354: Method For Adjusting Shims At Center Ball
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR ADJUSTING SHIMS AT CENTER BALL WARNING Place the work equipment lock lever at LOCK position except when operating the blade for adjustment. The shim adjustment of the center ball portion is required in the following cases. •...
Page 355: Checks Before Starting
MAINTENANCE PROCEDURE MAINTENANCE CHECKS BEFORE STARTING For the following items, see OPERATION, “METHOD FOR CHECKING BEFORE STARTING”. • Method for draining water and sediment from fuel tank • Method for checking water separator, draining water and sediment • Method for checking oil level in hydraulic tank, adding oil •...
Page 356: Every 50 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 50 HOURS MAINTENANCE METHOD FOR LUBRICATING NOTICE Perform the lubrication every 10 hours when the machine is operated on the soft ground, etc., and the soil and sand are accumulated on the machine. Lower the blade to the ground and stop the engine. By using a grease pump, pump in grease through the grease fittings.
Page 357: Method For Lubricating Equalizer Bar Center Pin
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR LUBRICATING EQUALIZER BAR CENTER PIN (1 place) Clean the grease fitting shown by arrow. 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} ...
Page 358: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 250 HOURS MAINTENANCE Maintenance for every 50 hours service should be performed at the same time. METHOD FOR LUBRICATING NOTICE Perform the lubrication every 10 hours when the machine is operated on the soft ground, etc., and the soil and sand are accumulated on the machine.
Page 359: Method For Checking Oil Level In Final Drive Case, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 360 If purified water is added to above U.L. line, use a syringe to lower the level to U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, con- sult your Komatsu distributor or a battery manufacturer. 4-47...
Page 361 (4). Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL ON INDICATOR ETC If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 362: Method For Checking Brake Performance
MAINTENANCE PROCEDURE METHOD FOR CHECKING BRAKE PERFORMANCE WARNING If the machine moves off during the following operation, ask your Komatsu distributor for repairs imme- diately. Before starting the engine, check the safety around the machine, and then perform the following operation.
Page 363: Every 500 Hours Maintenance
Tighten drain plug (P). Check the drained oil. If there are excessive metal particles or foreign material, contact your Komatsu distributor. Install cover (1). Remove the mounting bolts (4 pieces) from engine side cover (2) on the right side of the machine, and remove en- gine side cover (2).
Page 364 MAINTENANCE MAINTENANCE PROCEDURE Turn engine oil filter cartridge (3) counterclockwise by us- ing the filter wrench, and remove it. Clean the filter head. 10. Fill the new filter cartridge with clean oil, coat the packing face and thread with oil (or coat thinly with grease), then install the filter cartridge.
Page 365: Method For Replacing Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise 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.
Page 366 MAINTENANCE MAINTENANCE PROCEDURE When the O-ring has been replaced, coat the surface with clean fuel before installing it. 11. After the packing surface touches the seal surface of the filter cartridge, tighten transparent cup (4) 1/4 to 1/2 turn. REMARK If the transparent cup is fastened too much, the O-ring will be damaged and this leads to leakage of fuel.
Page 367 MAINTENANCE PROCEDURE MAINTENANCE Loosen the knob of feed pump (8), pull it out, then pump it in and out until the movement becomes heavy. REMARK • It is not necessary to remove the plugs at the fuel prefilter head and at the fuel main filter head. •...
Page 368: Method For Replacing Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC FILTERS Since the filtering ability of the filters decreases as they are aged, replace them every 500 operating hours or every year. METHOD FOR REPLACING RECIRCULATION AIR FILTER Turn knob (1) at the back of the operator's seat, and re- move recirculation air filter (2).
Page 369 MAINTENANCE PROCEDURE MAINTENANCE Turn knob (2) to open the inspection cover at the rear of the machine, and remove the fresh air filter. 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.
Page 370: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 1000 HOURS MAINTENANCE Maintenance for every 50, 250 and 500 hours should be performed at the same time. METHOD FOR CHANGING OIL IN FINAL DRIVE CASE WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury.
Page 371: Method For Replacing Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise 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.
Page 372 MAINTENANCE MAINTENANCE PROCEDURE Thinly apply oil to the packing surface of the new filter car- tridge, then install the filter cartridge to the filter head. Replace inner seal (3) with a new one. After the packing surface reaches the sealing surface of the filter head, tighten the filter cartridge 3/4 turns.
Page 373: Method For Replacing Fuel Tank Breather Element
(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. 4-60...
Page 374: Method For Replacing Hydraulic Tank Breather Element
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT Remove nut (2) of breather assembly (1) on the top of the hydraulic tank. Use a tool when the nuts are so tight to remove. Remove cover (3). Replace breather element (4) with a new one. Install cover (3) and nut (2).
Page 375: Method For Replacing Def Tank Breather Element
If the machine is operated without the DEF tank breather element attached, or with the element oth- er than Komatsu genuine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without the DEF tank breather element attached, nor use the element other than Komatsu genuine parts.
Page 376 MAINTENANCE MAINTENANCE PROCEDURE Remove mounting bolts (B), loosen (C), and change the angle of breather bracket (A). Remove nut (2) of breather assembly (1). Remove cover (3). Replace breather element (4) with a new one. 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.
Page 377: Method For Checking For Loose Rops Mount Bolts
Since the auto-tensioner is installed, tension adjustment is not required. Check the alternator drive belt. If alternator drive belt shows the following conditions, it must be replaced. Ask your Komatsu distributor to replace it. • When vertical flaw (2) that crosses horizontal flaw (1) is found.
Page 378: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE EVERY 2000 HOURS MAINTENANCE Maintenance for every 50, 250, 500 and 1000 hours service should be performed at the same time. METHOD FOR CHANGING OIL IN HYDRAULIC TANK, REPLACING HYDRAULIC OIL FILTER ELEMENT, REPLACING HST OIL FILTER CARTRIDGE, AND CLEAN- ING HYDRAULIC TANK STRAINER WARNING •...
Page 379 MAINTENANCE PROCEDURE MAINTENANCE Take out drain hose (2). Place the oil container to catch oil under drain hose (2). Loosen drain valve (P) and drain the oil. 10. Tighten drain valve (2). 11. Open the hydraulic tank inspection cover on the left side of the machine.
Page 380 MAINTENANCE MAINTENANCE PROCEDURE 20. Remove battery terminals (11) (4 places). 21. Remove battery mounting 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.
Page 381 41. After the packing surface touches the sealing surface of the filter head, tighten the filter cartridge 2/3 turns. Komatsu recommends using Komatsu genuine cartridge. 42. Add the refill capacity of oil through oil filler port (F). 43. Install the cap of oil filler port (F).
Page 382: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tor (For Control Circuit)
• 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 on the ma- chine.
Page 383 MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING FUNCTION OF ACCUMULATOR CAUTION When operating the blade control lever to lower the blade, check the safety around the machine. 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 on the ma- chine.
Page 384: Method For Checking Alternator
Check that the work equipment goes down to the ground under its own weight. In the following cases, the gas charge pressure of the accumulator has gone down. Contact your Komatsu dis- tributor. • Work equipment does not go down •...
Page 385: Method For Checking Vibration Damper
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING VIBRATION DAMPER Ask your Komatsu distributor for inspection of the vibration damper. METHOD FOR REPLACING KCCV FILTER ELEMENT WARNING After the engine has been operated, all of parts are still very hot. Do not replace the filter element imme- diately.
Page 386 MAINTENANCE MAINTENANCE PROCEDURE By using the special wrench, loosen ring (3) of KCCV ven- tilator (1). After ring (3) comes off, remove case (4) from body (2) and remove element (5). There may be oil accumulated or sticking in the case and element.
Page 387 MAINTENANCE PROCEDURE MAINTENANCE Align the position of ◇ mark (8) on the case with that of ◇ mark (11) of the filter body label, then install the case to the filter body. The element can be installed only when its claw (12) and claw (13) of the case are correctly inserted in groove (14) of the body.
Page 388: Method For Replacing Def Filter
Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without the DEF filter attached, or with the filter other than Komatsu gen- uine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine.
Page 389 MAINTENANCE PROCEDURE MAINTENANCE Turn cap (4) of filter removal tool (3) and remove it. Check the installation of spacer (5). Insert filter removal tool (3) into the bottom of the DEF pump and thrust in with hand. Check that filter removal tool (3) is fully inserted to the end. Insert the filter removal tool to the end where you cannot thrust it in any further.
Page 390 MAINTENANCE MAINTENANCE PROCEDURE Pull filter (6) up while pushing in the tip of filter removal tool (3), and remove it. Return the removed 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.
Page 391: Every 4000 Hours Maintenance
METHOD FOR CHECKING WATER PUMP Check around the water pump for water leakage. If any abnormality is found, ask your Komatsu distributor for repair or replacement of the parts. METHOD FOR CHECKING STARTING MOTOR Ask your Komatsu distributor to have the starting motor checked.
Page 392: Method For Replacing Accumulator (For Control Circuit)
• 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 continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 393: Method For Checking For Looseness Of Engine High-Pressure Piping Clamp, Hard- Ening Of Rubber
(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. • Replacement of the high-pressure piping must be made as an assembly.
Page 394 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. 4-81...
Page 395: Every 4500 Hours Maintenance
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. 4-82...
Page 396: Every 8000 Hours Maintenance
EVERY 8000 HOURS MAINTENANCE Maintenance for every 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. 4-83...
Page 397: Every 9000 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE EVERY 9000 HOURS MAINTENANCE 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. 4-84...
Page 398: Specifications
SPECIFICATIONS...
Page 399: Specifications: D61Ex-24
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS: D61EX-24 With power angle power tilt dozer, ROPS cab Item Unit D61EX-24 Machine weight kg { lb} 18440 {40660} Komatsu SAA6D107E-3 diesel Engine model engine SAE J1995 (gross) 127 {170} / 2200 {2200} kW { HP} / Rated horsepower min { rpm} ...
Page 400: Specifications: D61Px-24
SPECIFICATIONS SPECIFICATIONS: D61PX-24 With power angle power tilt dozer, ROPS cab Item Unit D61PX-24 Machine weight kg { lb} 19380 {42733} Komatsu SAA6D107E-3 diesel Engine model engine SAE J1995 (gross) 127 {170} / 2200 {2200} kW { HP} / Rated horsepower min { rpm} ISO 9249 / SAE J1349 (net)
Page 402: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 403: General Precautions
GENERAL PRECAUTIONS PRECAUTIONS FOR SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distrib- utor first.
Page 404: Handle Hydraulic Ripper
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER HANDLE HYDRAULIC RIPPER This ripper is applicable for D61EX. GENERAL VIEW (1) Hydraulic cylinder (4) Shank (2) Link (5) Point (3) Beam (6) Support...
Page 405: Explanation Of Components
HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER WARNING When performing inspection or maintenance of the machine, or when parking the machine, lower the ripper to the ground and set the work equipment lock lever to LOCK position. The ripper control lever is used for operating the ripper.
Page 406: Machine Operations And Controls
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER MACHINE OPERATIONS AND CONTROLS CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE METHOD FOR WALK-AROUND CHECK Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the pins.
Page 407 HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS Loosen lock plate mounting bolts (1) and remove lock plate (2). Lock plates (2) are at both ends of pin (3). Pull out pin (3). Change the position of the pin hole of the shank, and in- stall pin (3).
Page 408: Troubles And Actions
OTHER TROUBLE • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 409: Check And Maintenance
HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS CHECK AND MAINTENANCE EVERY 250 HOURS MAINTENANCE METHOD FOR LUBRICATING Lower the ripper to the ground and stop the engine. By using a grease pump, pump in grease through the grease fittings. After greasing, wipe off any old grease that is pushed out. (1) Ripper cylinder bottom pin (1 place) (2) Ripper cylinder rod end pin (1 place) (3) Link pin (8 places)
Page 410: Specifications: D61Ex-24
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER SPECIFICATIONS: D61EX-24 Power angle 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...
Page 411: Handle 3M Width Blade
HANDLE 3m WIDTH BLADE ATTACHMENTS AND OPTIONS HANDLE 3m WIDTH BLADE This blade is applicable for D61PX. GENERAL VIEW (1) Center blade (6) Shim (for offset lock pin) (2) Folding blade (right and left) (7) Shim (for hinge pin) (3) Lock plate (8) Lock plate fixing pin (4) Offset lock pin (9) Lock pin...
Page 412: Machine Operations And Controls
ATTACHMENTS AND OPTIONS HANDLE 3m WIDTH BLADE MACHINE OPERATIONS AND CONTROLS PROHIBITED OPERATIONS CAUTION • Use the 3 m wide blade for light dozing work or level- ing work. • Do not dig hard/frozen ground by using the right and left folding portions of the blade or perform severe work such as stumping, ditching, etc.
Page 413 HANDLE 3m WIDTH BLADE ATTACHMENTS AND OPTIONS METHOD FOR FOLDING BLADE WARNING When folding or unfolding the blade, observe the following items. • Place the machine on a firm and level place. Do not place the machine on a slope. •...
Page 414 ATTACHMENTS AND OPTIONS HANDLE 3m WIDTH BLADE Offset lock pin (1) and lock plate (2) are installed at the top and bottom of right and left ends of the center blade. (4 places in total) Remove offset lock pin (1) and shim (3) above it. Remove lock pins (6) from both ends of folding blade (5).
Page 415: Check And Maintenance
HANDLE 3m WIDTH BLADE ATTACHMENTS AND OPTIONS CHECK AND MAINTENANCE WHEN REQUIRED METHOD FOR ADJUSTING PLAY IN BLADE BOSS WARNING It is dangerous if the work equipment moves by mistake when the blade is adjusted. Set the work equipment in a stable condition, then stop the engine. Securely set the work equipment lock lever and parking brake lever to the respective LOCK positions.
Page 416: Specifications: D61Px-24
ATTACHMENTS AND OPTIONS HANDLE 3m WIDTH BLADE SPECIFICATIONS: D61PX-24 Power angle power 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"}...
Page 418: Replacement Parts
REPLACEMENT PARTS...
Page 419: Periodic Replacement Of Defined Life Parts
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. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 420: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 421 CONSUMABLE PARTS REPLACEMENT PARTS NOTICE When handling parts that weigh more than 25 kg {55.1 lb} , remember that they are heavy objects, and take the necessary care.
Page 422: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 423: Lubrication Chart
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS LUBRICATION CHART • The lubrication chart uses symbols to show the lubrication points and types of lubricant by each 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.
Page 424 REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT Symbol Meaning of the symbol Symbol Meaning of the symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check oil level in engine oil pan Change hydraulic oil Check hydraulic oil level Change oil in final drive case Replace final drive case Replace hydraulic oil filter and clean hy-...
Page 425: Method For Using Fuel, Coolant And Lubricants According To Ambient Tempera- Ture
ASTM D975 No. 1–D S15 Fuel tank Diesel fuel ASTM D975 No. 2–D S15 DEF tank DEF (Note.4) KES: Komatsu Engineering Standard ASTM: American Society of Testing and Material Specified capacity Refill capacity Reservoir Liter US gal Liter US gal Engine oil pan 7.66...
Page 426: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems in the cooling system, including the engine.
Page 428: Index
INDEX INDEX Symbols Basic operation of machine monitor......3-6 Battery..............3-246 12H24H display mode - Switch......3-86 Battery - Check electrolyte level from side....4-47 1st travel speed setting......... 3-49 Battery - Check electrolyte level impossible from side. 2nd travel speed setting........3-50 ...............4-48 3m width blade - Handle........6-10 Battery - Handle............
Page 429 INDEX Contents of safety labels.........2-4 Door damper - Replace.........4-34 Control levers and pedals........3-100 Door hinge - Lubricate.......... 4-34 Controls and gauges names........3-3 Door latch - Check..........4-34 Coolant..............3-245 Door lock striker - Check........4-35 Coolant - Check level / Add........ 3-156 Door open lock............3-107 Coolant and water for dilution.........
Page 430 INDEX Every 1000 hours maintenance......4-57 Fuse..............3-110 Every 2000 hours maintenance......4-65 Fusible link............3-112 Every 250 hours maintenance......4-45,6-8 Every 4000 hours maintenance......4-78 Every 4500 hours maintenance......4-82 Gauges - Watch..........3-215 Every 50 hours maintenance........ 4-43 Gear - Shift............3-203 Every 500 hours maintenance......
Page 431 Machine monitor - Operate when operator identifica- Komatsu Closed Crankcase Ventilation (KCCV) 3-135 tion function is available with skip....3-89 Komatsu Diesel Particulate Filter (KDPF) - Handle..Machine monitor - Operate when operator identifica- ..............3-125 tion function is available without skip.....3-91 Komatsu genuine lubricants........4-2...
Page 432 Precautions related to protective structure... 2-15 Pedal mode selector switch........3-46 Precautions to prevent fire........2-11 Perform KOWA (Komatsu Oil Wear Analysis)..4-8 Precautions when installing hydraulic hoses..4-3 Periodic replacement of defined life parts.....2-36 Precautions when leaving machine...... 2-14 Phenomena and actions for chassis....
Page 433 Radiator fin - Clean..........4-32 Sound control button...........3-234 Radiator fin / Oil cooler fin - Clean / Check...4-29 Specifications............5-2 Radiator front - Check / Clean......4-23 Specifications - D61EX-24........5-2,6-9 Radiator grille............3-116 Specifications - D61PX-24......5-3,6-15 Radiator grille - Close..........3-117 Speed range display..........3-36 Radiator grille - Open..........
Page 434 INDEX Track tension - Check / Adjust......4-24 Transportation..........3-239,6-11 Trees and stumps - Fell / Remove...... 3-218 Troubles and actions........3-250,6-7 Tuningtime adjustment button......3-233 Turn battery disconnect switch to off position..2-31 Two workers for maintenance when engine is running ...............2-29 Unauthorized modification........

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