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Komatsu D155AX-8E0, Operation & Maintenance Manual

The Komatsu D155AX-8E0 is a powerful construction machine designed for maximum efficiency and performance. Ensure proper operation with the Operation & Maintenance Manual, available for free download at 88.208.23.73:8080. This comprehensive manual provides essential information for safe and effective use of the equipment. Download your copy today.

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MAINTENANCE SCHEDULE

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

MAINTENANCE SCHEDULE TABLE

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) .......................................... 4-15
WHEN REQUIRED ........................................................................................................................................ 4-15

METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER.......................................... 4-15
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM ................................................................. 4-21
METHOD FOR CHECKING AND ADJUSTING TRACK TENSION ......................................................... 4-23
METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE BOLTS .......................... 4-26
METHOD FOR CHECKING IDLER CLEARANCE .................................................................................. 4-26
METHOD FOR INVERTING AND REPLACING CUTTING EDGE AND END BIT ................................... 4-27
METHOD  FOR  CLEANING  AND  CHECKING  RADIATOR  FIN,  OIL  COOLER  FIN,  AND  AFTERCOOLER

FIN ...................................................................................................................................................... 4-29

CHECK AND CLEAN AIR CONDITIONER CONDENSER INTAKE PORT.............................................. 4-33
METHOD FOR CLEANING FUEL FILLER PORT STRAINER ................................................................ 4-33
CLEAN POWER TRAIN CASE BREATHER ........................................................................................... 4-34
METHOD FOR CLEANING HYDRAULIC TANK BREATHER ................................................................. 4-34
METHOD FOR CLEANING FUEL TANK BREATHER............................................................................. 4-34
METHOD  FOR  CHECKING  AND  ADJUSTING  ALTERNATOR  AND  AIR  CONDITIONER  COMPRESSOR

BELT TENSION................................................................................................................................... 4-35

METHOD FOR CHECKING UNDERCARRIAGE OIL.............................................................................. 4-35
METHOD FOR REPLACING DOOR DAMPER....................................................................................... 4-36
METHOD FOR LUBRICATING DOOR HINGE........................................................................................ 4-37
METHOD FOR CHECKING DOOR LATCH ............................................................................................ 4-37
METHOD FOR CHECKING DOOR LOCK STRIKER.............................................................................. 4-37
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID ................................. 4-37
METHOD FOR REPLACING WIPER BLADE ......................................................................................... 4-38
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER................................................. 4-39
METHOD FOR CLEANING AIR CONDITIONER AIR FILTERS (FRESH/RECIRC) ................................ 4-40
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT .............................................................. 4-40
METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT ......................................................................... 4-42
METHOD FOR LUBRICATING ............................................................................................................... 4-43
METHOD FOR CHECKING ELECTRICAL INTAKE AIR HEATER .......................................................... 4-43
METHOD FOR CHECKING AND REPLACING RIPPER SHANK ........................................................... 4-43

CHECKS BEFORE STARTING...................................................................................................................... 4-44
EVERY 250 HOURS MAINTENANCE ........................................................................................................... 4-44

METHOD FOR LUBRICATING ............................................................................................................... 4-44
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL ..................................... 4-46
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL ............................................................. 4-47
METHOD  FOR  CHECKING  AND  ADJUSTING  ALTERNATOR  AND  AIR  CONDITIONER  COMPRESSOR

BELT TENSION................................................................................................................................... 4-50

METHOD FOR CHECKING BRAKE PERFORMANCE........................................................................... 4-50

EVERY 500 HOURS MAINTENANCE ........................................................................................................... 4-51

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

............................................................................................................................................................ 4-51

METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................... 4-53
METHOD FOR REPLACING ELEMENT ON POWER TRAIN OIL FILTER ............................................. 4-55
METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC FILTERS ....................................... 4-55

EVERY 1000 HOURS MAINTENANCE ......................................................................................................... 4-56

METHOD  FOR  CHANGING  OIL  IN  POWER  TRAIN  CASE,  CLEAN  POWER  TRAIN  PUMP  STRAINER

AND SCAVENGING PUMP STRAINER .............................................................................................. 4-56

METHOD FOR REPLACING POWER TRAIN CASE BREATHER .......................................................... 4-58
METHOD FOR CHANGING OIL IN FINAL DRIVE CASE ....................................................................... 4-59
METHOD FOR LUBRICATING UNIVERSAL JOINT ............................................................................... 4-59
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE ............................................................ 4-60

MAINTENANCE

MAINTENANCE SCHEDULE

4-13

Summary of Contents for D155AX-8E0

Page 1: ...th Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all perso...

Page 2: ......

Page 3: ...uine new Komatsu or Ko matsu approved rebuilt parts or assemblies or others parts of equivalent quality and that the engine be serviced by an authorized Komatsu distribu tor Failure to follow these re...

Page 4: ...enance Manual Storing Place It is provided on the back side of the operator s seat back If this manual is lost or damaged contact Komatsu or your Komatsu distributor and tell them about the machine mo...

Page 5: ...ng the processing of your personal data i e storage collection transfer etc of all information that relates to you as operator to the party with whom you have most direct relationship In principle thi...

Page 6: ...tion 4 above For the purposes a to l as indicated in section 4 above as well as for the purpose of informing a third party in the context of a possible merger acquisition or demerger the processing of...

Page 7: ...t data b the processing is illegitimate or c the data are no longer needed for the pur poses which are outlined above but you need them to defend yourself in judicial proceedings You have the right to...

Page 8: ...safety mes sage This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word indicates a potentially hazardous situation wh...

Page 9: ...of the standard deviation of the meas ured time averaged A weighted emission sound pressure level at the operator s position is 2 5dB in accordance with ISO 11201 Sound power level emitted by the mach...

Page 10: ...lic system and linkages 3 Keep the terrain where the machine is working and travelling in good condition Remove any large rocks or obstacles Fill any ditches and holes Site manager should provide mach...

Page 11: ...Do not repeatedly handle and lift loads FOREWORD VIBRATION LEVELS 1 9...

Page 12: ...perator s seat 1 in the direction of travel front of the machine 1 Operator s seat A Front B Rear C Left D Right VISIBILITY FROM OPERATOR S SEAT Risk assessment has been carried out based on the visib...

Page 13: ...Evaluation height 1 2m above the ground Scale interval of the circles is 1 m FOREWORD INTRODUCTION 1 11...

Page 14: ...Exhaust Fluid into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water About Diesel...

Page 15: ...CT IDENTIFICATION NUMBER PIN MACHINE SERI AL NO PLATE This is under the front of the console box on the right side of the operator s seat The design of the nameplate differs according to the district...

Page 16: ...SE GASES Product contains fluorinated greenhouse gases Standard spec Wide air condensor spec LOCATION OF RIPPER SERIAL NO PLATE This is on the left side face of ripper beam HFC 134a GWP 1430 CO2 eq kg...

Page 17: ...L NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Manufacturers name Address KOMATSU LTD 2 3 6 Akasaka Minato ku Tokyo 107 8414 Japan Authorised representa...

Page 18: ...B D F G H EI000001 A MACHINE DESIGNATION TYPE E ENGINE POWER B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER C YEAR OF CONSTRUCTION G MANUFACTURER D OPERATING MASS H AUTHORISED REPRESENTATIVE SERIAL P...

Page 19: ...EUROPE INT Mechelsesteenweg 586 B 1800 Vilvoorde Belgium Declares that this machine D155AX 8E0 Fulfils all the relevant provisions of following EC Directives Machinery Directive 2006 42 EC Electro Ma...

Page 20: ...Y LABELS 2 5 CONTENTS OF SAFETY LABELS 2 6 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2 12 PRECAUTIONS BEFORE STARTING OPERATION 2 12 PREPARATIONS FOR SAFE OPERATION 2 12 PRECAUTIONS TO P...

Page 21: ...IPPER 3 193 OPERATING METHOD FOR RIPPING WORK 3 195 METHOD FOR ADJUSTING WORK EQUIPMENT 3 199 TIPS FOR LONGER UNDERCARRIAGE LIFE 3 203 METHOD FOR PARKING MACHINE 3 206 METHOD FOR CHECKING AFTER FINISH...

Page 22: ...S 4 9 HANDLE HYDRAULIC COMPONENTS 4 9 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4 11 MAINTENANCE SCHEDULE 4 13 MAINTENANCE SCHEDULE TABLE 4 13 MAINTENANCE PROCEDURE 4 15 INITIAL 250 HOURS MAINTENA...

Page 23: ...METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA TURE 7 6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7 8 INDEX 8 1 FOREWORD TABLE OF CONTENTS 1 21...

Page 24: ......

Page 25: ...se 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 s...

Page 26: ...S CAB 2 16 ELECTROMAGNETIC INTERFERENCE 2 16 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 17 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 17 UNAUTHORIZED MODIFICATION 2 17 PRECAUTIONS RELATED TO ATTACHMENT...

Page 27: ...1 PRECAUTIONS FOR CHECK AND MAINTENANCE 2 31 TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 2 31 PRECAUTIONS FOR WELDING 2 32 HANDLE BATTERY 2 32 PRECAUTIONS WHEN USING HAMMER 2 33 PRECAUTIONS FOR HIG...

Page 28: ...ly When cleaning the safety labels do not use organic solvents or gasoline These may cause the labels to peel off If the safety labels are damaged lost or cannot be read properly replace them with new...

Page 29: ...r handling ROPS FOPS 4 Caution for adjusting track tension 5 Stop rotation during inspection and maintenance 6 Caution for approaching while moving machine 7 Caution for handling accumulator 8 Caution...

Page 30: ...radiator or hydraulic tank will cause personal injury and or burns Never remove the radiator cap or hydraulic tank oil filter when cooling water or hydraulic oil is at high temperatures 2 Caution for...

Page 31: ...n tenance 09667 A0481 Sign indicates a hazard of rotating parts such as belt Turn off before inspection and maintenance 6 Caution for approaching while moving machine 09806 B1683 Sign indicates a haza...

Page 32: ...d take engine key with you before leaving ma chine 9 Caution for handling battery 10 Caution for moving in reverse 09833 B0881 only when equipped with camera When backing up rear of machine is display...

Page 33: ...potter if view is obstructed Follow above even if the machine is equipped with back up alarm and mirrors 12 Caution for operation inspection and maintenance 09651 A0641 Warning Read the manual before...

Page 34: ...9808 A0881 Sign indicates an electric hazard from handling the cable Read the manual for safe and proper handling 16 Caution against high pressure fuel 6271 81 2981 Do not open high pressure fuel syst...

Page 35: ...fuel 19 Caution for high temperature hydraulic oil 09653 A0481 Never remove the cap when the engine is at operating high temperature Stream or high temperature oil blowing up from the radiator or hydr...

Page 36: ...ERATION PRECAUTIONS FOR SAFETY RELATED EQUIPMENT Be sure that all guards covers cameras and mirrors are in their proper position Repair them immediately if they are damaged Understand the using method...

Page 37: ...re Do not use a cellular phone when driving or operating the machine This may lead to mistakes in operation and may cause serious personal injury or death Never bring any dangerous objects such as fla...

Page 38: ...in the specified place and do not allow unauthorized persons to enter When performing grinding or welding work on the machine move any flammable materials to a safe place before starting Fire caused...

Page 39: ...r off the machine Use the handrails and steps indicated by arrow B only when moving along the top of the track or when checking or performing maintenance inside the side cover or when filling the tank...

Page 40: ...eath PRECAUTIONS WHEN LEAVING MACHINE If the proper procedures are not taken when parking the machine the machine may suddenly move off by itself and this may lead to serious personal injury or death...

Page 41: ...illed in it or it is modified in any other way its strength may drop Any modification is prohibited If the protective structure is damaged or deformed by falling objects or by rolling over its strengt...

Page 42: ...rt or operate the engine in a place where there is good ventilation If the engine or ma chine must be operated inside a building or underground where the ventilation is poor take steps to ensure that...

Page 43: ...obstruct travel PRECAUTIONS WHEN WORKING ON LOOSE GROUND Avoid driving or operating the machine near the edge of cliffs road edges and deep ditches The ground may be weak in such areas If the ground...

Page 44: ...places with poor visibility always observe the following Allocate a signalman for jobsite duty if there are areas where the visibility is poor Only one signalman should give signals When working in da...

Page 45: ...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 per...

Page 46: ...can cause a serious personal injury or death Check that there are no persons or obstacles above below or in the area around the machine PRECAUTIONS WHEN STARTING ENGINE The machine may suddenly move o...

Page 47: ...h the machine For the starting procedure with the jumper cables see OPERATION START ENGINE WITH JUMPER CA BLES 3 244 PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are...

Page 48: ...ations always keep a safe distance from people structures or other machines to avoid coming into contact with them When traveling on a level ground keep the work equip ment approximately 40 to 50 cm a...

Page 49: ...e following precau tions Perform operation when the machine is set with safe angles and the machine is stable It is dangerous if you travel with high speed while performing operation on a slope Travel...

Page 50: ...ays observe the fol lowing Place the machine on a firm level ground Select a place where there is no hazard of landslides falling rocks or flooding Lower the work equipment to the ground When leaving...

Page 51: ...he ground correct the di rection then enter the ramps again The center of gravity of the machine will change suddenly at the joint between the ramps and the loading platform and there is danger of the...

Page 52: ...e clean the tidy to enable you to perform operations safely If the work place is not kept clean and tidy there is the danger that you will trip slip or fall over and injure your self SELECT SUITABLE P...

Page 53: ...osition set work equip ment lock lever 1 to FREE position F operate the work equipment control lever to RAISE and LOWER position a few times repeatedly to release the remaining pressure in the hydraul...

Page 54: ...NG ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments Place attachments that have been removed from the ma chine in a stable condition so that they do not...

Page 55: ...the work equipment or the ma chine and then go under it to perform inspection or mainte nance support the work equipment and machine securely with blocks and stands strong enough to support the weigh...

Page 56: ...ry from the machine take it to a well ventilated place remove the battery caps then perform the charging After charging tighten the battery caps securely Danger from dilute sulphuric acid When the bat...

Page 57: ...remove the cap PRECAUTIONS FOR HIGH TEMPERATURE OIL To prevent burns from hot oil spurting out or from touching high temperature parts when checking or draining the oil wait for the oil to cool down t...

Page 58: ...ause fire or defective operation It is dangerous and may cause serious personal injury or death If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount stop operati...

Page 59: ...owerful spring that acts to reduce the impact on the idler 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...

Page 60: ...G OF WASTE MATERIALS 2 36 and MAINTENANCE OF AIR CONDITIONER 2 36 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution pay full attention to the way to dispose of waste materials Always d...

Page 61: ...l and cause serious personal injury or death It is difficult to judge the remaining life of these components from external inspection or the feeling when operating so always replace them at the specif...

Page 62: ...n tainer for storage Only open containers in a well ventilated area When storing DEF avoid direct sunlight Always use the original container it came in Do not exchange the con tainer of DEF with anoth...

Page 63: ...OPERATION Please read and make sure that you understand the SAFETY section before reading this section 3 1...

Page 64: ...1 Blade 2 Blade lift cylinder 3 Cab 4 Ripper tilt cylinder 5 Multi shank ripper 6 Track 4 Final drive 8 Track frame 9 Frame 10 Blade tilt cylinder 11 DEF injector 12 Idler 13 Ripper lift cylinder 14...

Page 65: ...ing brake lever 3 Fuel control dial 4 Joystick steering directional and gear shift lever 5 Rear lamp switch 6 Headlamp switch 7 Machine monitor 8 Starting switch 9 Engine shutdown secondary switch 10...

Page 66: ...ge display 15 Operation mode pilot lamp 16 Air conditioner pilot lamp 17 Preheating pilot lamp 18 Fan reverse rotation pilot lamp 19 Reverse travel slow mode pilot lamp 20 Dual tilt mode pilot lamp 21...

Page 67: ...REMARK The above figure does not show all of the caution lamp symbols For details of the caution lamps see WARN ING DISPLAY 3 13 OPERATION GENERAL VIEW 3 5...

Page 68: ...1 Warning display 2 Meter display 3 Gear speed display part 4 Monitor switch area 5 Guidance display 6 Guidance icon display 7 Pilot display REMARK For the user menu used for setting various items of...

Page 69: ...ng screen BB After the check before starting screen BB is displayed for 2 seconds the screen switches to the preset starting gear speed display screen HH After the preset speed range when moving machi...

Page 70: ...ayed and engine does not start If engine shutdown secondary switch 1 is turned OFF nor mal the machine monitor switches to the standard screen and you can start the engine with usual starting switch k...

Page 71: ...perator identification function with SKIP is set the opening screen GG switches to ID number input screen LL with SKIP when the starting switch is turned to ON position If inputting ID number for oper...

Page 72: ...If inputting incorrect ID number for 3 times continuously you cannot input ID number for 5 minutes Wait for more than 5 minutes try inputting ID number again As long as ID number input screen is displ...

Page 73: ...efore starting screen BB for 2 seconds the screen changes to the mainte nance time warning screen CC After displaying the maintenance time warning screen CC for 30 seconds the screen returns to the st...

Page 74: ...Current Abnormality screen is displayed BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any abnormality occurs during operation the standard screen AA changes to the...

Page 75: ...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 If no action is taken the machine can be seriously affected Tak...

Page 76: ...y displayed starting from the leftmost side of the screen ACTION LEVEL DISPLAY Action level display 1 indicates the degree of urgency of the abnormalities currently generated on the machine by L01 to...

Page 77: ...AMP 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...

Page 78: ...al L01 Transmission system caution lamp Abnormal L04 L03 Abnormal L01 KDPF system caution lamp Abnormal L04 L03 Abnormal L01 KDPF soot accumulation caution lamp Abnormal L03 Accumulated L01 DEF level...

Page 79: ...peed L02 Radiator coolant level caution lamp Low coolant level L01 Charge level caution lamp Abnormal L03 Air cleaner clogging caution lamp Clogged L01 Air conditioner system caution lamp Abnormal L01...

Page 80: ...iate remedies according to the displayed mes sage Operation on the Current Abnormality screen On the Current Abnormality screen you can perform the follow ing operations with switches F1 F2 and F5 F1...

Page 81: ...s up in red and indicates action level L02 The power train oil temperature has risen abnormally high While this lamp is lit the overheat prevention system is auto matically actuated and the engine spe...

Page 82: ...nctions may be restricted for use but the machine can operate When you finish the operation always perform the inspection and maintenance Ask your Komatsu distributor for inspection and maintenance as...

Page 83: ...em When action level L04 is displayed The caution lamp lights up in red and the alarm buzzer sounds continuously Stop the machine immediately and ask your Komatsu distribu tor for inspection and maint...

Page 84: ...ork 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 Some functions may be...

Page 85: ...avoid advancing to the next Inducement status With No Action level display DEF tank level is becomes low Warning starts Inducement status is Warning Need to add DEF immediately When Lightning in whit...

Page 86: ...nning it at low idle for approximately 5 minutes Ask your Komatsu distributor for the inspection and maintenance as needed PARKING BRAKE SYSTEM CAUTION LAMP The parking brake system caution lamp warns...

Page 87: ...level L04 is displayed The caution lamp lights up in red and the alarm buzzer sounds continuously Stop the machine immediately and ask your Komatsu distribu tor for inspection and maintenance When ac...

Page 88: ...from the radiator For the inspection and maintenance ask your Komatsu distributor CHARGE LEVEL CAUTION LAMP Charge level caution lamp warns about abnormality in the charging system while the engine i...

Page 89: ...caution lamp lights up in red The maintenance time is over If no action is taken the machine performance will become worse and the machine life will be shortened Perform necessary maintenance as soon...

Page 90: ...display 8 Working mode display 9 Air conditioner pilot lamp 10 Preheating pilot lamp 11 Fan reverse rotation pilot lamp 12 Reverse travel slow mode pilot lamp 13 Dual tilt mode pilot lamp 14 Floating...

Page 91: ...heating is for a maximum of approximately 40 seconds FAN REVERSE ROTATION PILOT LAMP The fan reverse rotation pilot lamp lights up while the fan is ro tating in reverse For the reverse rotation of the...

Page 92: ...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 comb...

Page 93: ...nt lock pilot lamp lights up when the work equipment lock lever is in LOCK position It goes out when the work equipment lock lever is set in FREE position If it is required to set the work equipment l...

Page 94: ...uto idle stop function see AUTO IDLE STOP TIMER SETTING 3 76 Guidance To Avoid Hydraulic Relief If the hydraulic oil is kept relieved for more than 10 seconds during operation the hydraulic relief det...

Page 95: ...tomatic shift recommendation guidance goes out in 5 seconds or when switch F5 is pressed DEF low level guidance At 15 seconds after the starting switch is turned to ON position and the standard screen...

Page 96: ...tilt mode is not selected the machine is set in the single tilt mode Select the mode with F1 key FLOATING MODE PILOT LAMP The float mode pilot lamp lights up when the machine is in the float mode How...

Page 97: ...ee CUSTOMIZE SWITCH 3 44 The function is enabled disabled with the work equipment auto mation switch Display of the auto pitch pilot lamp varies with setting of the function and operation of the machi...

Page 98: ...speed is too high Decrease the travel speed in this case A to B Red range A to C Green range For other items displayed by the multi gauge see METHOD FOR USING MULTI GAUGE 3 58 ENGINE COOLANT TEMPERAT...

Page 99: ...to B Red range A to C Green range C to D White range The overheat prevention system operates as follows Red range A position Power train oil temperature caution lamp E shows abnormality display Red r...

Page 100: ...green range NOTICE When the indicator comes close to red range A during operation run the engine at low idle or stop it and wait for the hydraulic oil temperature to drop Display H when temperature is...

Page 101: ...he engine speed By pressing switch F4 on the standard screen you can switch the clock display and service meter display REMARK If the battery is disconnected for a long period for storage etc the time...

Page 102: ...onsumption gauge shows the average fuel consumption of the machine A Shows the average fuel consumption of a day from 0 00 a m of the day to 0 00 a m of the next day B Shows the split fuel consumption...

Page 103: ...turn the starting switch to OFF position Wait for a while after adding then turn the starting switch to ON position MONITOR SWITCHES 1 Function switch 2 Operation mode selector switch 3 Buzzer cancel...

Page 104: ...tor switch C Switch F3 Camera image selector switch D Switch F4 Service meter clock display selector switch E Switch F5 Current Abnormality list display switch While the caution lamp is displayed F Sw...

Page 105: ...eturns to the previous screen M Switch F6 Accepts any selection and change contents and goes to the next screen REMARK Even if some icons look the same their display positions and corresponding functi...

Page 106: ...top of the screen CUSTOMIZE SWITCH k k CAUTION To ensure safety always stop the machine before operating the customize mode Press the customize switch and the customize mode selection screen is displ...

Page 107: ...n example of the setting change screen when the working mode is selected 3 After changing the setting of each item press switch F2 The memory saving screen is displayed 4 Check the setting of each ite...

Page 108: ...E SELECTOR SWITCH The gear shift mode selector switch changes the gear shift mode to automatic shift mode or manual shift mode In the au tomatic shift mode the transmission shifts up automatically to...

Page 109: ...e properly for digging and dozing Since the pitch angle does not need manual control the operator s fatigue is reduced The operator can enable disable this function by using the work equipment automat...

Page 110: ...de is pitched back fully to digging or dozing Q positions dur ing reverse travel even if the operator does not push the auto pitch button If the operator changes the blade pitch angle with the work eq...

Page 111: ...tion is finish ed 2 Auto pitch function stops To start the auto pitch operation again after each operation is finished push auto pitch button P again Digging position set mode While the machine is tra...

Page 112: ...oes not operate when oper ation forward travel is only ripping work Also pitches back fully to digging or dozing Q position when auto pitch button P is pushed 1 Auto pitch function is interrupted Auto...

Page 113: ...ly blue B Lift and tilt independent operation blue C Lift and tilt interlocked operation green D Function OFF background color of symbol The ripper auto return pilot lamp lights up in yellow while the...

Page 114: ...e the machine is traveling in reverse after the ripper control lever is set in LIFT RAISE position a the ripper rises to the stroke end automatically even if the ripper con trol lever is returned to N...

Page 115: ...l operation is performed Lift only While the machine is traveling in reverse after the ripper control lever is set in LIFT RAISE position a the ripper rises to the stroke end automatically even if the...

Page 116: ...opera tion Normal operation Normal operation Operation 1 Operation 1 1 Ripper auto return stops if manual operation is performed FUNCTION SWITCHES The operation of the function switches in the standar...

Page 117: ...creen the screen automatically returns to the camera im age display For details of the air conditioner operation see HANDLE AIR CONDITIONER 3 211 It is possible to change the operation mode by pressin...

Page 118: ...r does not stop sounding by pressing the buzzer cancel switch It is possible to turn the blade auto pitch and ripper auto return functions ON OFF by pressing the work equipment automation switch For t...

Page 119: ...p is flashing if no lever is operated for 10 seconds or more the screen automatically returns to the standard screen When the screen returns to the standard screen the cau tion lamp at the top left of...

Page 120: ...yed press switch F4 to switch to the clock display DUAL TILT MODE SWITCH Only machines equipped with dual tilt function When function switch F1 is pressed the dual tilt mode is se lected When it is pr...

Page 121: ...ution lamp 6 Drawbar pull 7 Load graph 8 Pitch graph 9 Clock display Approximate values indicated by the multi gauge are as follows Engine speed 1 500 rpm 2 1000 rpm 3 1500 rpm 4 2000 rpm 5 2625 rpm 6...

Page 122: ...the ECO gauge it is recommended to use in green range G The graphs on the screen are updated and scrolled to the left at intervals of several seconds The latest information is dis played at the right...

Page 123: ...lowing kinds Press switches F1 and F2 to move to right and left for selecting menu screens a Energy Saving Guidance b Machine Setting c Aftertreatment Devices Regeneration d SCR Information e Maintena...

Page 124: ...ons 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...

Page 125: ...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 F2 Moves to the right menu When on the right end menu it mov...

Page 126: ...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 Operat...

Page 127: ...ergy Saving Guidance menu 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 Oper...

Page 128: ...ek Operation on the Average Fuel Consumption Record screen Press switch F1 F2 or F5 on the Average Fuel Consumption Record screen to perform the following operations F1 Clears the graph data F2 Switch...

Page 129: ...n during the last 1 week Switching be tween them is available Deleting the average fuel consumption records 1 When switch F1 CLEAR is pressed the reconfirmation screen shown in the figure is displayed...

Page 130: ...gurations screen On the Configurations screen it is possible to perform the fol lowing operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the fi...

Page 131: ...moves to the last line F5 Cancels the setting and returns to Configurations screen F6 Changes the setting and returns to Configurations screen 2 The Average Fuel Consumption Display screen appears 1...

Page 132: ...reen When you stop the measurement move from Energy Saving Guidance menu a screen to the Operation Records 1 screen or ECO Guidance Records 2 screen then press the measure ment stop switch F1 STOP SWI...

Page 133: ...the setting and returns to Configurations screen F6 Changes the setting and returns to Configurations screen SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE It is possible to change the targe...

Page 134: ...it is possible to perform the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line a...

Page 135: ...possible to perform the following oper ations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line above...

Page 136: ...e fuel control dial is set to High idle MAX position but this is not a failure The hydraulic fan reverse mode fan reverse rotation can be used to remove insects and dirt sticking to the radiator core...

Page 137: ...ersing operation press switch F5 10 Since fan reverse rotation is set start the engine After the engine is started the machine monitor screen displays as shown in the figure If the parking brake lever...

Page 138: ...ine is running normally The parking brake lever and work equipment lock lever are in LOCK positions The engine coolant temperature hydraulic oil temperature and power train temperature are high and th...

Page 139: ...set the parking brake lever or work equipment lock lever to FREE positions countdown stops and the screen returns to the standard screen 4 When countdown reaches 0 the engine stops and the screen cha...

Page 140: ...500 P T Oil Filter Change 500 Fuel Main Filter Change 1000 Hydraulic Tank Breather Change 1000 P T Oil Change 1000 P T Case Breather Change 1000 Final Drive Oil Change 1000 Hydraulic Oil Pilot Filter...

Page 141: ...y C is highlighted in yellow If the time remaining to the maintenance is less than 0 hour display C is highlighted in red If you want to change the setting for the maintenance time or maintenance noti...

Page 142: ...the Monitor Set ting menu screen F6 Accepts the change and returns to the Monitor Set ting menu screen REMARK If the light switch is at night mode ON and the screen is adjusted it is possible to adju...

Page 143: ...n be set Camera image screen brightness adjustment Camera view mode setting Setting of Reverse Synchroni zation Guide line display mode setting On this screen it is possible to perform the following o...

Page 144: ...ent Cam era menu 2 Press switch F6 3 The Camera View Mode setting screen is displayed Normal Switch F2 of the function key is used to change the screen to the camera screen Reverse Synchronization Cam...

Page 145: ...it is possible to perform the following operations with switches F3 to F6 F3 Moves to the next item 1 line below When on the last line it moves to the first line F4 Moves to the previous item 1 line a...

Page 146: ...d time in accordance with the clock of GPS F3 Moves to the next item 1 line below Moves to the top line when on the bottom line F4 Moves to the previous item 1 line above Moves to the bottom line when...

Page 147: ...6 F3 Calendar goes back 1 month F4 Calendar advances 1 month F5 Cancels change and returns to the year setting screen F6 Proceeds to setting for date 4 When date display C is highlighted in yellow ope...

Page 148: ...epts change and returns the screen to Clock Ad justment screen SWITCH 12H 24H DISPLAY MODE Choose either a 12 hour display AM PM or a 24 hour display 24 hour system display 12 hour system display AM P...

Page 149: ...t 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 Norweg...

Page 150: ...on function WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted the identified ID is displayed in the column of Operator ID on the Monitor Se...

Page 151: ...D is not identified When you press switch F6 after inputting the ID which is not registered to the Operator ID Change screen a message is displayed below and the screen returns to the Monitor Setting...

Page 152: ...etting menu screen In this case the identified ID is not changed On the Operator ID Change screen if no switch is operated for more than 30 seconds the screen auto matically changes to the Monitor Set...

Page 153: ...sage the message display lights up in blue B The message will be deleted when it becomes out of date or when a new message arrives CHECK MESSAGE 1 Press switch F6 on the standard screen When there is...

Page 154: ...rd screen 2 After inputting a selected item number press switch F6 3 When the message Do you send Numeric Input is dis played in the column 1 of the mail confirmation menu screen press switch F6 again...

Page 155: ...tarts When the preheat pilot lamp changes from lighting to flashing release the key immediately When the switch is released it automatically returns to OFF position A Turn the starting switch key to S...

Page 156: ...al caught in arm or blade Snow or ice sticking to arm or blade This is also used as the window washer switch The switch is operated as follows Switches LH FF RH and RR a ON position The wiper operates...

Page 157: ...lack D For front colorless E Washer tube tank side F Washer tube cab side G Left door blue H Right door red I Rear window black J Front window colorless HORN SWITCH If you press the horn switch the ho...

Page 158: ...PULLER OPERATION SWITCH only machines equipped with giant ripper The pin puller operation switch is used to operate the ripper shank pin a Pull The pin is pulled out b Push The pin is pushed in F Fron...

Page 159: ...the switch cover is closed and the switch is in the NORMAL position If not set it to the NOR MAL position 1 Raise cover C and open it 2 Turn the engine shutdown secondary switch to upper posi tion a...

Page 160: ...ith single tilt This mode is used for lifting and tilting the blade Lifting control a RAISE b HOLD Blade is held at current position c LOWER d FLOAT button Blade is moved freely by external force REMA...

Page 161: ...mp M is not lit the machine is set in the single tilt mode Lifting control a RAISE b HOLD Blade is held at current position c LOWER d FLOAT button Blade is moved freely by external force p Pitch switc...

Page 162: ...lit Pitching control Reverse pitch blade edge angle is small Set pitch switch p toward E Forward pitch blade edge angle is large Set pitch switch p toward D Auto pitch Auto pitch is a function to set...

Page 163: ...touched by mistake it may lead to serious personal injury or death If the parking brake lever is not in LOCK position se curely the parking brake may not be locked Check that the parking brake lever i...

Page 164: ...e blade control lever or ripper control lever The work equipment lock lever is a locking device of the blade control lever and the ripper control lever When operating the work equipment lock lever alw...

Page 165: ...machine turns gradually If the lever is tilted fully the machine turns sharply REMARK If the lever is released during steering operation it returns to a or b and the machine travels straight Gear shi...

Page 166: ...attention to interference with obstacles during opera tion When the lever is tilted halfway in the direction you are turning while it is in N Neutral the R H and L H track shoes rotate in the opposite...

Page 167: ...ripper point to the ripping posture automatically Since the operator does not need to keep tilting the lever or holding down the switch he she is less fatigued For detail see RIPPER AUTO RETURN 3 50 O...

Page 168: ...oors securely The doors may be closed by vibration SASH GLASS INTERMEDIATE LOCK When working with the cab sash glass open use this lock to prevent the glass from chattering When the lever is in FREE p...

Page 169: ...eces and wash them in water ASHTRAY The ashtray is on the left side of the operator s seat Always put out your cigarette before putting it in the ashtray and be sure to close the lid POWER SUPPLY OUTL...

Page 170: ...then turn the battery discon nect switch to OFF position The fuses protect the electrical component and wiring from burning out If the fuse becomes corroded or white powder can be seen or the fuse is...

Page 171: ...C air conditioner 10 20 A Key ACC spare 11 20 A Sensor power source relay 1 12 10 A Sensor power source relay 2 13 15 A Fuel feed pump 14 15 20 A DEF line heater relay 1 16 10 A DEF line heater relay...

Page 172: ...jects soon after it is pushed in check the electrical circuit REMARK A circuit breaker is a circuit protection device installed to a high voltage current circuit Similarly to an ordinary fuse it prote...

Page 173: ...of the reset button Do not hold down the reset button of the circuit breaker for a long time If the starting motor does not operated after the circuit breaker is restored contact your Komatsu distrib...

Page 174: ...em is cut out and the functions of KOM TRAX stop In addition the time information of the clock and the radio tuning information may be lost In this case set the information again For detail see CLOCK...

Page 175: ...he 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 Also keep combustible material...

Page 176: ...then perform hydraulic fan reverse operation For the operation to reverse the hydraulic fan rotation see MACHINE SETTINGS 3 73 2 types of machine monitor require the manual stationary regeneration dep...

Page 177: ...ce noncombustible matter which cannot be burnt by the regeneration is accumulated in the filter of KDPF the filter needs to be cleaned or replaced at regular intervals See METHOD FOR CLEANING KDPF 4 8...

Page 178: ...soot accumulation caution lamp 2 lights up in yellow stop the machine in a safe place after finishing the operation and perform the manual stationary regeneration When the degree of emergency is high...

Page 179: ...running 2 Check that there is no person or combustible matter around the machine particularly in the direction of the ex haust gas flow 3 Set the parking brake lever and work equipment lock lever to...

Page 180: ...soot accumulation caution lamp is lit the accumulat ed soot may not be burnt sufficiently and the filtering func tion may not be improved Wait until the Aftertreatment De vices Regeneration pilot lamp...

Page 181: ...ne monitor during this regeneration It is completed in approxi mately 10 minutes If the parking brake lever and work equipment lock lever or the fuel control dial is operated during the manual station...

Page 182: ...the failure of KDPF or the engine While regeneration is not being performed Setting for the regeneration disable When the aftertreatment devices regeneration pilot lamp is lit on the standard screen 1...

Page 183: ...amp 3 may light up but this does not indi cate abnormality Also during the regeneration to protect the system the regeneration disable cannot be operated When the regeneration is performed to protect...

Page 184: ...egeneration screen is displayed If the screen is not displayed operate function switch F1 and F2 and display the Aftertreatment Devices Regenera tion screen 2 Select the Cancel of the regeneration dis...

Page 185: ...hydrolyzes to form ammonia NH3 and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water The Komatsu Urea SCR System continuously monitors its operation conditio...

Page 186: ...em automatically starts operating as soon as the engine is started Even after the engine starting switch is turned to the OFF position the devices will still be in operation for sever al minutes to pu...

Page 187: ...will light up audible alert will start then Action level will be dis played on the machine monitor and engine power will be derat ed in steps In Action Level L03 Low level Inducement and L04 Severe I...

Page 188: ...2 gradations of the DEF level gauge light up in the red range DEF level caution lamp 1 lights up in red No Action level is displayed Press F6 to display the SCR Information screen Inducement status 4...

Page 189: ...vere Inducement and it becomes necessary to restore engine power use the engine power restoration function to move the machine to a safe place and add DEF Inducement strategy when abnormalities are de...

Page 190: ...hts up in yellow Note Action Level L01 once shows up in yellow on the machine monitor 2 for two seconds and goes out Press F6 to display the SCR Information screen SCR Information screen message 4 1 P...

Page 191: ...ine power deration capability of the ma chine will be limited Move the machine to the safe place and contact your Ko matsu Distributor The duration of Low level Inducement is 10 hours The remaining ti...

Page 192: ...and Action Level displayed on the machine monitor 3 au dible alert by a buzzer and stepwise engine power deration that advances to speed limitation to low idle Engine power deration starts with Action...

Page 193: ...The DEF system caution lamp 2 lights up in yellow The action level L03 lights up in red at action level dis play 3 Press F6 to display the SCR Information screen SCR Information screen message 5 2 Wit...

Page 194: ...system abnormality is not performed engine performance will kept be derated Engine power can be restored temporarily from power derate This engine power restoration works only when the Inducement stat...

Page 195: ...tent of the warning can be checked on the SCR Information screen of the user menu Perform the following procedure Press F6 on the standard screen to display the SCR Informa tion screen of the user men...

Page 196: ...e of Continuous Warning is 5 hours The remaining time Hours and Minutes till the next Induce ment status of Low level Inducement is displayed in the column 6 of SCR Information screen In Low level Ind...

Page 197: ...use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor Temporary Restoration from Inducement Temporary Restoration from Inducement is the o...

Page 198: ...Temporary Resto ration from inducement is displayed in the column 1 of the pop up menu window B 4 Press F6 while the Engine power Recovery window is displayed Temporary Restoration from Inducement is...

Page 199: ...ducement other than the amount of DEF in the tank If another abnormality abnormalities is detected within 40 hours after the previous abnormalities were corrected regardless of the level of the previo...

Page 200: ...sing satellite communication or portable radio communication The GPS Global Positioning System receiver and communication system are equipped in the vehicle man agement system The machine information...

Page 201: ...he machine has been lent out by the customer the borrower or another third party may have been using the KOMTRAX Confirm with the lessor about using condition of KOMTRAX Komatsu may suspend KOMTRAX co...

Page 202: ...irt accumulated around the engine and radiator Also check for combustible materials dry leaves twigs etc around the battery exhaust pipe aftertreatment devices turbocharger or other high temperature e...

Page 203: ...e rearview camera if equipped Check the rearview camera for any abnormality If any problem is found ask your Komatsu distributor for repair 14 Removal dirt from around the aftertreatment devices Check...

Page 204: ...r sediment is accumulated drain them according to the following procedure 1 Put a container to receive the water under drain hose 3 2 Loosen plug 4 and drain the water 3 When fuel starts draining from...

Page 205: ...he tilt cylinder length is the value in the table below Lower ripper b to the ground with the pin at the bottom so that the length of each cylinder is the value in the table below Reference Item Dimen...

Page 206: ...ce 1374 mm Ripper VGR VMR Lift cylinder length 1477 mm Tilt cylinder length 1431 mm 3 Approximately 5 minutes later check the oil level with sight gauge G If the oil level is between H and L of sight...

Page 207: ...low add coolant of the same density in radiator according to the coolant density table in METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 4 21 then add coolant to reservoir tank 1 Check that the engine...

Page 208: ...er or emulsified matter may stick to the dipstick fuel filler cap etc or the drained oil may be milky white because of water vapor in the blowby gas However if the coolant level is normal it is not a...

Page 209: ...e if the oil level is between marks H and L The levels for engine stopped and low oil temperature COLD STOP and for engine idling and high oil tempera ture HOT IDLE are marked on both sides of the dip...

Page 210: ...achine is inclining make it level before checking Perform oil level check while the engine is stopped 1 Open the engine side cover on the left side of the machine and cover 1 2 Pull out dipstick G and...

Page 211: ...lapped over the red zone A clean or replace the element immediately For the cleaning method of the element see METHOD FOR CHECKING CLEANING AND REPLACING AIR CLEANER 4 15 REMARK Clean or replace the...

Page 212: ...ery and remove such combustible material METHOD FOR CHECKING FUEL LEVEL ADDING FUEL k k WARNING When adding fuel never spill the fuel or let it overflow It may cause fire If any fuel has spilled wipe...

Page 213: ...performing operations on a slope or traveling on a rough ground When the remaining DEF level is low it may become the warning level if DEF pump sucks air or if DEF level suddenly drops If DEF is stor...

Page 214: ...ons The cap of filler port is opened 6 By sight gauge 3 add DEF through the filler port until float 4 reaches line F 5 Refill capacity of DEF tank 39 Line 6 in the sight gauge indicates approximately...

Page 215: ...F carefully while checking the sight gauge Add only DEF in clearly marked DEF tanks that have the blue cap METHOD FOR CHECKING LAMPS OPERATION 1 Turn the starting switch to ON position B 2 Set the hea...

Page 216: ...basic monitor screen is displayed If they do not light up the machine monitor may be defective or open circuit is in the machine monitor Ask your Komatsu distributor for the inspection METHOD FOR REM...

Page 217: ...the starting switch to OFF position A METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR S SEAT k k WARNING When adjusting the position of the operator s seat always set the work equipment lock lever...

Page 218: ...and set the seat back to a position which is comfortable for operation Foremost reclining Approx 66 Approx 1 9 x 35 steps Rearmost reclining Approx 72 Approx 1 9 x 38 steps Sit with your back against...

Page 219: ...e seat is moved backward turn knob 1 to adjust Weight adjustment range 60 to 150 kg 2 After adjusting the weight return the crank of knob 1 2 Adjust the height by turning knob 1 in the green range The...

Page 220: ...d unlock it When using the ripper the operator can work easily by directing the seat to the right 1 Pull up the direction adjustment lever to FREE position F and unlock it The seat direction can be ch...

Page 221: ...ost reclining Approx 72 Approx 1 9 x 38 steps Sit with your back against the backrest when adjusting If your back is not touching the backrest it may suddenly move forward 2 After adjusting release th...

Page 222: ...ion is adjusted to your weight automatically The air pressure in the sus pension increases or decreases according to your weight METHOD FOR ADJUSTING LUMBAR SUPPORT Turn the adjustment knob to the rig...

Page 223: ...ticular adjust so that you can see persons at the rear ends of the right and left sides of the machine METHOD FOR ADJUSTING JOYSTICK STEERING DIRECTIONAL AND GEAR SHIFT LEVER PCCS LEVER k k WARNING Af...

Page 224: ...wn below After adjusting the operator s seat adjust them to proper height METHOD FOR ADJUSTING RIGHT ARMREST R H armrest 1 can be adjusted to 20 mm and 40 mm above and 20 mm below the standard height...

Page 225: ...just the length CHECK SEATBELT Check for looseness of the mounting bolts of the metal fittings which are installing the seatbelt to the machine If the bolts are loosened retighten them The specified t...

Page 226: ...ure park ing brake lever 1 and work equipment lock lever 5 are secured in LOCK position When leaving the operator s seat be sure to set park ing brake lever 1 and work equipment lock lever 5 to the LO...

Page 227: ...hen joystick steering directional and gear shift lever 2 is not in N neutral position the engine does not start 4 Check that blade control lever 3 is in HOLD position b 5 Check that ripper control lev...

Page 228: ...een 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 1 The buzzer sounds for a...

Page 229: ...me has passed for certain items maintenance time caution lamp 21 is lit for 30 seconds Press switch F6 22 to check the item and perform main tenance immediately For details of the method of checking t...

Page 230: ...startup even if fuel control dial 1 is operated Even if the engine is started with the fuel control dial is not in Low idle MIN position the engine speed is set to low idle MIN In this case you can ch...

Page 231: ...he engine Never use starting aid fluids as they may cause explosions Exhaust gas is toxic When starting the engine in confined spaces be particularly careful to ensure good ventilation NOTICE Do not t...

Page 232: ...ver is not set to LOCK position L the engine cannot be started 2 Check that the work equipment lock lever is in LOCK posi tion L 3 Turn fuel control dial 1 to Low idle MIN position When the dial is in...

Page 233: ...mp varies with the ambient temperature as shown in the table Ambient temperature Lighting time sec 5 to 10 C 20 to 27 10 to 20 C 27 to 40 20 to 30 C 40 8 When the engine starts release the starting sw...

Page 234: ...ion operate at the same time the turbo protection function is given priority When the turbo protect function is actuated the engine speed is held at 1 000 rpm rpm even if the fuel control dial is turn...

Page 235: ...may damage the engine or confuse the operator s sense of driving or lower the braking effi ciency and as a result lead to an unexpected accident In that case ask your Komatsu distributor to check the...

Page 236: ...and engine If it is necessary to run the engine at idle apply a load from time to time or run at a medium speed If the engine oil pressure caution lamp on machine monitor 2 lights up and the buzzer so...

Page 237: ...o load for approximately 10 minutes 2 Raise the blade to the highest position and hold it by oper ating blade control lever 2 Relieve the oil intermittently for approximately 10 minutes with the blade...

Page 238: ...to cool down gradually and then stop it If the engine is stopped during the aftertreatment devices regeneration the components may be damaged Stop the aftertreatment devices regeneration first accord...

Page 239: ...si tion while the engine is still hot guidance 3 may be displayed on the machine monitor To cool down the engine before stopping run it at low idle for approxi mately 5 minutes because it may cause da...

Page 240: ...ssing brake pedal 8 even after you set parking brake lever 1 free When starting on a steep uphill slope turn fuel control dial 5 to High idle MAX position and run the engine at high idle keep depressi...

Page 241: ...ipper to the upper limit 5 Turn fuel control dial 5 to High idle MAX position and in crease the engine speed 6 Depress decelerator pedal 6 fully 7 Set the joystick steering directional and gear shift...

Page 242: ...leaving the operator s seat always secure work equipment lock lever 2 in LOCK position 1 Depress brake pedal 3 to apply the brake NOTICE If you depress the brake pedal when the engine speed or travel...

Page 243: ...displayed in the speed range display sec tion When the parking brake lever is locked P is displayed OUTLINE OF GEAR SHIFT MODE There are automatic shift mode and manual shift mode in the gear shift mo...

Page 244: ...automatic mode 4 Mark displaying automatic mode B Manual shift mode 5 Present speed range 6 Preset speed range when moving machine off 7 MAN mark displaying manual mode 8 Mark displaying manual mode...

Page 245: ...r shift lever is in N Neutral position if you press the up switch twice F1 R2 mode is selected Then when the joystick steering directional and gear shift lever is titled for ward forward travel operat...

Page 246: ...tion of the machine For example when the machine starts by shifting from N to F3L on a uphill ground the speed range may be shifted from N to F2 and then to F3L according to the load In automatic shif...

Page 247: ...ll sudden ly increase speed so depress the decelerator pedal to reduce the speed when dumping the load In the manual shift mode when the automatic down shift is ON the speed range is shifted down auto...

Page 248: ...ng downhill travel the machine may start in the 1st speed range depending on its condition For example if you shift the gear from F2 to R2 while depressing the decelera tor pedal the speed range may c...

Page 249: ...n 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 When performing counter rotation tu...

Page 250: ...here the track frame top is above the water surface If the cooling fan enters water it may be broken In particular take care that the machine does not pitch forward A Allowable water depth After worki...

Page 251: ...d fuel im mediately A Red range B Green range Pay attention to oil level When operating machine on sloped areas of more than 20 fill all appropriate components with oil to H level Pay attention to DEF...

Page 252: ...ed to FLOAT when the engine is running at low speed or when it is idling hunting may occur Raise the engine speed when performing FLOAT operation PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STR...

Page 253: ...e work lateral direction on a slope start the work from higher side If you raise the blade high the machine may tip over or it side slips It is dangerous Keep the blade height lower than 20 to 30 cm f...

Page 254: ...ard 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 tilting the blade For trees with a di...

Page 255: ...boulders or a hard rock bed use the tilt cylinder It is very important for effective use of the ripper to select proper ripper points according to the rock condition Since various ripper points are p...

Page 256: ...n 1 F Front of machine 4 Pull out the mounting pin If the mounting pin is not pulled out by the switch opera tion move the ripper up and down and tilt it a little and the mounting pin is pulled out ea...

Page 257: ...2 Lower the ripper point to the point to start ripping and raise the rear part of the machine 3 Depress the decelerator pedal and decrease the engine speed 4 Set the gear speed to F1 and penetrate th...

Page 258: ...hen the ripper point contacts the cliff tilt in the ripper 2 RIP BASE OF SLOPE When giant ripper is installed In ripping of the base of a slope if the ripper tilt back angle is small and uncrushed por...

Page 259: ...UP LARGE BOULDER If you encounter a large boulder which you cannot break easily and the shoes slip during ripping work dig it up according to the following procedure 1 Depress the decelerator pedal De...

Page 260: ...hape If the machine is steered during ripping the shank may be broken Before steering pull the shank out of the ground Never travel the machine in reverse while ripper point 1 is in the rock bed The p...

Page 261: ...lt distance exceeds 920 mm excessive force is applied to various portions and machine can be damaged Accordingly adjust with int 920 mm When the optional wide shoe is installed adjust the brace length...

Page 262: ...e brace you can easily adjust it by put ting it onto a block and turning the brace handle Since the blade is tilted in this operation the handle be comes heavy gradually In this case return the blade...

Page 263: ...joints to increase angle A of blade edge or decrease distance L to reduce angle A of blade edge Standard angle A of blade edge is 50 Standard distance L between the joints is 1360 mm Angle A of blade...

Page 264: ...pin half way by hand first then drive and fit it with a hammer When installing the giant ripper see PIN PULLER OPERATION SWITCH 3 96 METHOD FOR REPLACING POINT AND PROTECTOR k k WARNING For safety do...

Page 265: ...ecessary high speed operation or sharp turn Travel as straight as possible Do not turn only in either direction but turn in both directions evenly Also secure turning radius as large as possible Clear...

Page 266: ...ent of track tension Check the idler and rollers for oil leakage and loose bolts and nuts Repair abnormality immediately if any Check clearance B between idler guide plate 1 and track frame 2 As clear...

Page 267: ...IAMETER 1 Measure the link tread dimension C as shown in the fig ure 2 Stop the machine at a position where the link tread at which dimension C was measured is perfectly in contact with the roller tre...

Page 268: ...leaving the operator s seat always set work equipment lock lever 7 to LOCK position 1 Depress brake pedal 1 to apply the brake NOTICE If you depress the brake pedal when the engine speed or travel spe...

Page 269: ...ETHOD FOR CHECKING AFTER FINISHING WORK CHECKS BEFORE STOPPING ENGINE On the machine monitor check the engine coolant tempera ture hydraulic oil temperature power train oil temperature en gine oil pre...

Page 270: ...side 1 place on rear side Cab door opener 3 Cap with lock 4 Oil filler cap of hydraulic tank Power train oil filler pipe cap if equipped Reservoir tank inspection cover 5 Toolbox storage cover 6 DEF t...

Page 271: ...CAP 1 Raise lever 1 in the direction a 2 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 1...

Page 272: ...over tool box storage cover DEF tank inspection cover and water separator inspection cover Position A OPEN Position B CLOSE LOCK METHOD FOR LOCKING COVER WITH LOCK 1 Close the cover and insert the key...

Page 273: ...culation air to warm the inside of the cab After that turn the air conditioner switch ON the air conditioner will work If any abnormality is detected in any equipment or sensor used on the air conditi...

Page 274: ...used for stopping the fan and air conditioner REMARK Even if this OFF switch is pressed the monitor screen does not switch to the air conditioner adjustment screen FAN SWITCH You can adjust the air f...

Page 275: ...e can be set in stages of 0 5 C Monitor display and function Monitor display C Set temperature 18 0 Max cooling 18 5 to 31 5 Adjusts temperature inside cab to set temperature 32 0 Max heating REMARK I...

Page 276: ...and left 1 places C2 Front window glass vent 1 place Air blows out from the vents marked with LCD display Air vent mode Vent Remarks A B C Front and rear vents Front rear and foot vents Foot vent Foot...

Page 277: ...but this is not a problem FRESH RECIRC AIR SELECTOR SWITCH Use FRESH RECIRC air selector switch to switch the air source between recirculation of the air inside the cab and in take of fresh air from...

Page 278: ...conditioner Air conditioner cannot be operated while the fan is stop ped SUNLIGHT SENSOR Sunlight sensor automatically adjusts the flow of air from the vents to match the strength of the sun s rays In...

Page 279: ...ly selected according to the set temperature and the air conditioner is operated auto matically to provide the set temperature REMARK When vent monitor c displays d or e and engine coolant temperature...

Page 280: ...djust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Turn air conditioner switch 2 ON 3 Use temperature control switch 3 to set to the desi...

Page 281: ...e monitor changes according to the selection 5 Press FRESH RECIRC selector switch 5 and select recir culation of the air inside the cab RECIRC or intake of fresh air from outside FRESH METHOD FOR STOP...

Page 282: ...r blow ing to the feet set as follows 1 Press fan switch 1 and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector sw...

Page 283: ...3 Turn air conditioner switch 2 ON 4 Adjust fan switch 1 temperature control switch 3 and FRESH RECIRC selector switch 5 to the desired posi tions OPERATION HANDLE AIR CONDITIONER 3 221...

Page 284: ...djust the air flow When doing this check that temperature setting a and air flow b are displayed on the monitor 2 Press vent selector switch and set vent display on the dis play monitor to f or g as s...

Page 285: ...ure control switch 1 and set temperature on the monitor to 32 0 of maximum heating 5 When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify...

Page 286: ...splay selector button 7 Sound control button 8 Display POWER BUTTON Press the power button to supply the power to the radio and the frequency is shown on display As long as AUX is selected display ind...

Page 287: ...are displayed B Frequencies are displayed at steps of 50 kHz in certain areas C Lights up when a stereo broadcasting is heard while a FM station is selected D Lights up at the time of balance adjustme...

Page 288: ...d down the button and the frequency increases continuously hold down the button and the fre quency decreases continuously Hold down the button and release it then the fre quency increases continuously...

Page 289: ...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...

Page 290: ...ress the button and the low register range bass level decreases by 1 Minimum 7 METHOD FOR ADJUSTING CLOCK 1 Press display selector button 1 to display the clock 2 Hold down display selector button 1 t...

Page 291: ...urface If the flat track shoes cannot be prepared always place boards to protect the road surface even when traveling a short distance Note that the asphalt road becomes soft in summer PRECAUTIONS FOR...

Page 292: ...loading or unloading the machine be sure to use ramps or platform and follow the procedure shown be low PROCEDURES FOR LOADING MACHINE Load on a firm and level ground 1 Park a trailer on a firm and l...

Page 293: ...uitable strength by method A or B to prevent the machine from moving during transportation In particular fix the machine securely to prevent it from slipping sideways Place wire rope protection pads o...

Page 294: ...rdingly pass the border slowly and carefully Drive down the ramps slowly and carefully until the ma chine leaves the ramps perfectly METHOD FOR LIFTING MACHINE k k WARNING The person using the crane t...

Page 295: ...t of the machine as shown in the figure NOTICE Put protectors etc to the sharp corners and the portions where the wire ropes are caught to pre vent breakage of the wire ropes Use a spreader beam havin...

Page 296: ...ge interval and the density of Non Amine Engine Coolant AF NAC see METH OD FOR CLEANING INSIDE OF COOLING SYSTEM 4 21 DEF NOTICE DEF freezes at 11 C If DEF in DEF tank freezes it may expand to break t...

Page 297: ...the rod from getting inside the seal Place the machine on a firm dry ground If this is impossible park the machine on boards The boards prevent the tracks from freezing to the ground and allow the mac...

Page 298: ...If the machine is parked for long time in the cold weather condition quality of DEF may be affected by repeated freeze ask your Komatsu distributor to inspect COLD WEATHER OPERATION OPERATION 3 236...

Page 299: ...a short distance once a month so that a new film of oil will coat moving parts At the same time charge the battery as well When operating the work equipment wipe off all the grease from the hydraulic...

Page 300: ...stem has any abnormality stop the engine and then start it again If SCR system still has abnormality after the engine is restarted contact your Komatsu distributor If DEF is kept in DEF tank for more...

Page 301: ...cut strands A re duced diameter B or kinks C There is a danger that the rope may break during the towing operation Always wear leather gloves when handling the wire rope Never tow a machine on a slope...

Page 302: ...g wire rope to the towing hook as shown in the figure on the right If the machine is equipped with the counterweight install the wire rope to the towing hook of the counterweight Connect a wire rope t...

Page 303: ...ur eyes wash the eyes immediately with clean water then consult a doctor for medical treat ment When handling batteries always wear protective eye glasses and rubber gloves When removing the battery f...

Page 304: ...ect the wiring from the battery 7 After replacing the battery secure it with the battery hold down fittings Tightening torque 4 places First nuts A 4 to 6 Nm 0 4 to 0 6 kgm Second nuts B 30 to 50 Nm 3...

Page 305: ...Set the charging current to 1 10 of the value of the rat ed battery capacity when performing rapid charging set it to less than the rated battery capacity If the charger current is too high the electr...

Page 306: ...y as that of the failed machine Check the cables and clips for damage or corrosion Make sure that the cables and clips are firmly connected Check that the lock levers and parking brake levers if equip...

Page 307: ...mn 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 Lamp does not glow brightly eve...

Page 308: ...e air heater Replace Defective operation of heater relay Check repair heater relay Defective operation of air conditioner Fuse blow Check repair Insufficient battery charge Charge battery Defective ai...

Page 309: ...avel straight Defective adjustment of power train controller Adjust Defective steering valve Check replace Torque converter overheats power train oil temperature caution lamp lights up Power train cas...

Page 310: ...cap or replace packing Defective monitor Replace monitor Starting motor turns but engine does not start Lack of fuel Add oil to specified level See CHECK BEFORE STARTING Air in fuel system Repair port...

Page 311: ...chine has not run out of fuel if CA2249 or CA559 appears on the Current Abnormality screen re place both fuel main filter element and fuel prefilter ele ment immediately If CA2249 or CA559 does not di...

Page 312: ......

Page 313: ...MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section 4 1...

Page 314: ...ng oil or fuel PRECAUTIONS FOR ADDING DEF Do not remove the strainer while adding DEF It is recommended to use a nozzle having a diameter and a length specified by ISO 22241 4 and an auto stop functio...

Page 315: ...h the lock bar etc If inspection or maintenance is performed with inspection cover not locked in position there is a danger that it may be suddenly shut by the wind and cause personal injury PRECAUTIO...

Page 316: ...chine and get caught in the lever linkage mechanism Are there any leakage of coolant or oil Have all nuts and bolts been tightened Checks while the engine is running For details of the checks when the...

Page 317: ...ntry of such impurities Take particular care not to let any impurities get in when storing or adding oil Never mix oils of different grades or brands Always add the specified amount of oil Having too...

Page 318: ...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 an...

Page 319: ...om mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual Grease fittings not included in the periodic maintenance secti...

Page 320: ...sheet or take other measures to protect them To prevent any change in quality during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first STORE DEF Comp...

Page 321: ...omatsu recommends installing electric components specified by Komatsu External electro magnetic interference may cause malfunction of the control system controller Accordingly consult your Komatsu dis...

Page 322: ...ned or when a hydraulic component is repaired replaced or its piping is removed air in the circuit must be bled The accumulator is charged with high pressure nitrogen gas and it is extremely dangerous...

Page 323: ...bolt a mm Width across flats b mm Tightening torque Target value Allowable range Nm kgm Nm kgm 6 8 10 12 14 10 13 17 19 22 13 3 31 67 111 172 1 35 3 2 6 8 11 3 17 5 11 8 to 14 7 27 to 34 59 to 74 98...

Page 324: ...7 to 245 18 0 to 25 0 10 33 41 216 22 0 177 to 245 18 0 to 25 0 Face seal Nominal No of hose Nominal size thereads per inch a Width across flats b mm Tightening torque Target value Allowable range Nm...

Page 325: ...CHECKING DOOR LOCK STRIKER 4 37 METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL ADDING FLUID 4 37 METHOD FOR REPLACING WIPER BLADE 4 38 METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER 4 39 METHOD FO...

Page 326: ...LAMPS 4 79 EVERY 4000 HOURS MAINTENANCE 4 79 REPLACE DEFINED LIFE PARTS 4 79 METHOD FOR CHECKING WATER PUMP 4 80 METHOD FOR CHECKING ALTERNATOR 4 80 METHOD FOR CHECKING STARTING MOTOR 4 80 METHOD FOR...

Page 327: ...ers into the engine and damages it Be sure to stop the engine before performing these works When using compressed air there is a danger that dirt may scatter and cause personal injury Al ways wear pro...

Page 328: ...rect sunlight 1 Open the engine side cover on the left side of the machine 2 Undo latches 2 6 places and remove cover 3 3 Remove outer element 4 NOTICE Never remove inner element 5 If it is removed di...

Page 329: ...cleaned or new element for adhesion of dusts and oil Wipe them off if any NOTICE Do not clean and reuse inner element 5 When replacing outer element 4 replace the inner element with new one as well I...

Page 330: ...ement 2 Lock the tip of hook 2 on the protrusion of the air cleaner body 3 Lock hooks 2 diagonally top and bottom right and left in the same way as when tightening bolts 4 When cover 3 is installed ch...

Page 331: ...well If the outer element 4 and cover 3 are installed while the inner element 5 is not installed proper ly the outer element 4 may be damaged The sealing portion of the improper part lacks pre cision...

Page 332: ...3 Lock hooks 2 diagonally top and bottom right and left in the same way as when tightening bolts 4 When cover 3 is installed check that the clearance between the air cleaner body and cover 3 is not to...

Page 333: ...t AF NAC Every 2 years or 4000 hours whichever comes sooner The coolant has the important function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an iss...

Page 334: ...catch drained coolant Prepare a hose to use when filling with coolant and water The specified coolant volume including reservoir tank 104 1 Slowly turn the cap 1 of radiator coolant filler port 2 Plac...

Page 335: ...3 145 13 Stop the engine 14 After 3 minutes add Non Amine Engine Coolant AF NAC up to the mouth of the coolant filler port 1 Add all the specified volume of Non Amine Engine Coolant AF NAC If the ref...

Page 336: ...osen plug 1 more than 1 turn If plug 1 is loosened more than 1 turn there is a danger of plug 1 flying out under the high internal pressure of the grease Never loosen any part other than plug 1 Never...

Page 337: ...el stuck to the back of cover 2 When removing cover 2 be careful not to let dirt in 1 Remove both bolts 3 2 pieces and then remove cover 2 2 Loosen plug 1 gradually to release the grease When loosenin...

Page 338: ...ighten by 110 to 130 METHOD FOR RETIGHTENING MASTER LINK CONNECTING BOLT 1 Tighten the master link connecting bolts in the order shown in the figure Tightening torque for master link connecting bolt 5...

Page 339: ...BIT k k WARNING It is dangerous if the work equipment moves by mistake when the cutting edge or end bit is being re placed Set the work equipment in a stable condition set the work equipment lock lev...

Page 340: ...nd portion a of mounting plate b may be worn However the wear of this portion does not affect the serv ice life of the blade Semi U dozer U dozer The symbols of the work equipment are as follows A Sem...

Page 341: ...5 to 1000 Nm 75 to102 kgm 4 When installing end bit 4 fit its top end 5 to stopper 6 and tighten the bolt 8 After operating several hours retighten the mounting nut METHOD FOR CLEANING AND CHECKING RA...

Page 342: ...displayed to inform the operator that the direction of rotation of the fan has not been changed Stop the engine once and follow the steps 2 and 3 above 5 Turn the starting switch 1 to START position a...

Page 343: ...is not rotating If you touch the fan when it is rotating it will cause serious personal injury or death NOTICE When using compressed air for cleaning blow it keeping some distance to avoid damaging t...

Page 344: ...r looseness METHOD FOR CLEANING OIL COOLER FIN If the hydraulic oil cooler fins are clogged with dirt check and clean them 1 Open engine side covers 1 on both sides of the machine 2 Blow off mud dirt...

Page 345: ...eformed and this will cause early clogging and breakage of the equipment 4 Perform the following check Check the rubber hoses If they are cracked or fragile replace them Check the hose clamps for loos...

Page 346: ...eather is found dirty at inspection or maintenance clean it 1 Remove nut 2 of breather assembly 1 on the top of the hydraulic tank 2 Remove cover 3 3 Remove dirt sticking to breather element 4 4 Clean...

Page 347: ...Check the belt and replace it with a new one in the following cases The belt is cracked or peeled The belt is worn and split lengthwise 1 Loosen lock nut 2 of push bolt 1 2 Tighten push bolt 1 fully 3...

Page 348: ...ut perform the following step 2 REMARK Seal bolt 1 of the idler is not seen until the outside side cover is removed 2 Remove seal bolt 1 If no oil oozes the oil level is low Ask your Komatsu dis tribu...

Page 349: ...icient or dried out apply new grease to inside of the latch through portion 1 REMARK If the grease in the latch is dried out the latch does not move normally because of dust in it and the operating ef...

Page 350: ...uid METHOD FOR REPLACING WIPER BLADE If the blade is damaged the windshield is wiped unevenly In this case replace the blade METHOD FOR REPLACING FRONT WIPER 1 The blade is hooked on portion A Move it...

Page 351: ...rigerant leaking point If the level of the refrigerant gas is low the cooling effect will be reduced Perform while running the engine at high idle and operating the air conditioner at high speed Check...

Page 352: ...the pleats NOTICE If there is a small hole or a thin portion on the filter re place the filter If the pleats of each filter or the seal of the fresh air fil ter is damaged replace it as well REMARK S...

Page 353: ...5 Loosen bleeder 2 6 When air and hydraulic oil containing air do not flow out of bleeder 2 any more tighten bleeder 2 METHOD FOR BLEEDING AIR FROM CYLINDER 1 Start the engine Run the engine at low i...

Page 354: ...e 1 of the fuel tank is opened S CLOSE O OPEN 3 Tilt switch for the fuel feed pump 2 to ON position Lamp 3 flashes and the electric fuel feed pump operates After the specified time approximately 7 min...

Page 355: ...Lower the work equipment to the ground 2 Stop the engine 3 Remove the cover under the monitor and control panel 4 By using a grease pump pump in grease through the grease fittings shown by arrows Fue...

Page 356: ...k oil level in hydraulic tank add oil Check coolant level add coolant Check oil level in engine oil pan add oil Check oil level in power train case add oil Check oil level in damper case add oil Check...

Page 357: ...gh the track frame and track shoe A 3 Supply grease from above the track shoe NOTICE After working in water or swampy ground grease each part Greasing equalizer bar center pin 1 place 1 Open the engin...

Page 358: ...2 Lift cylinder bottom pin 1 place 3 Tilt cylinder rod end pin 1 place 4 Lift cylinder rod end pin 1 place 5 Arm pin front side 2 places 6 Arm pin rear side 2 places METHOD FOR CHECKING OIL LEVEL IN F...

Page 359: ...ar the battery 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 Do not use a dry wipe to clean the battery...

Page 360: ...PER LEVEL U L 5 After adding the purified water tighten cap 3 securely REMARK If the purified water is added to above UPPER LEVEL U L line remove the fluid by using a syringe to lower the level to UPP...

Page 361: ...rolyte surface to bulge and pole plate appears to be warped B Low level Electrolyte level does not reach the bottom of sleeve so pole plate appears straight and not to be warped 5 After adding the pur...

Page 362: ...eration ask your Komatsu distributor for repairs imme diately NOTICE Never set the joy stick steering directional and gear shift lever to the 1st speed range This will cause damage to the machine Befo...

Page 363: ...injury Accordingly wait until they have cooled down before starting the work Refill capacity 37 Prepare a socket wrench and a filter wrench If the operating hours do not reach 500 hours in 6 months re...

Page 364: ...that there is no old packing stuck to the filter holder If there is any old packing stuck to it it will cause leakage of oil 9 When installing the cartridge tighten it until the packing surface contac...

Page 365: ...the conventional injection pump and nozzles If any cartridge other than a Komatsu genu ine filter cartridge is used dust or dirt may get in and cause problems with the injection system Never use a su...

Page 366: ...r the packing will be damaged and this will lead to leakage of fuel If the filter cartridge is tightened too loose fuel will also leak from the packing so always tighten to the specified angle When ti...

Page 367: ...ACING 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...

Page 368: ...ver 2 and tighten knobs 1 EVERY 1000 HOURS MAINTENANCE Maintenance for every 250 and 500 hours services should be performed out at the same time METHOD FOR CHANGING OIL IN POWER TRAIN CASE CLEAN POWER...

Page 369: ...undercover at the rear of the machine bottom according to the following procedure 1 Remove bolts 4 2 pieces on the front side of the ma chine 2 While holding down the cover gradually remove bolts 5 2...

Page 370: ...e and the parts taken out as well 13 Install the strainer as before If the spring or strainer is broken replace them 14 Replace the power train oil filter element See METHOD FOR REPLACING ELEMENT ON P...

Page 371: ...drained oil 3 Remove oil level plug 2 and oil filler plug 3 remove drain plugs 1 and 4 and drain the oil 4 After draining the oil install drain plugs 1 and 4 Tighten the drain plugs securely 5 Add oil...

Page 372: ...ne to let the internal pressure go down before replacing the filter Do not bring any open flame close NOTICE Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filte...

Page 373: ...tall the cartridge to the filter head 3 NOTICE Do not fill the new filter cartridge with fuel Remove cap C at center and install the filter car tridge 7 When installing the cartridge tighten it until...

Page 374: ...air from only the filter head is required However if the fuel piping is removed bleed air from the injection pump air bleeding valve as well METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT 1 Remove n...

Page 375: ...raulic tank to release the internal pressure in the hydraulic tank 2 Open the L H side cover and remove cover 1 3 Remove bolts 2 and remove cover 3 4 Place a container to catch drained oil under the f...

Page 376: ...ilter case 4 then tighten filter case 4 Tightening torque 25 to 35 Nm 2 6 to 3 6 kgm 8 Install cover 3 as it was with bolts 2 9 Install cover 1 and close the L H side cover METHOD FOR CHECKING AND CLE...

Page 377: ...genuine parts foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine Never operate the machine in such condition Do not flush DEF tank breather element Flus...

Page 378: ...5 to 8 5 Nm 0 66 to 0 87 kgm METHOD FOR CHECKING DRIVE BELT TENSION PULLEY ASSEMBLY FOR AL TERNATOR AND AIR CONDITIONER COMPRESSOR METHOD OF CHECKING Check the pulley for play and grease leakage If a...

Page 379: ...f the cover so that you can easily get out of the way Refill capacity 1 5 1 Open engine side cover 1 on the left side of the machine 2 Open inspection cover 2 Dipstick G is seen 3 Remove inspection co...

Page 380: ...e still very hot and may cause burn in jury Accordingly wait until they have cooled down before starting the work When removing the oil filler cap the oil may spout out Turn it slowly to release the i...

Page 381: ...osening drain valve 2 be careful not to get splashed with oil 7 After draining the oil tighten drain valve 2 and drain plug 1 8 Loosen cover 3 mounting bolts 6 pieces 9 Remove cover 3 At this time the...

Page 382: ...own and then re move drain plug 1 loosen drain valve 2 and drain excessive oil 22 Install the cap 23 After draining oil bleed the air from the hydraulic circuit See METHOD FOR BLEEDING AIR FROM HYDRAU...

Page 383: ...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 f...

Page 384: ...stops you can release only just after the engine stops 4 With the work equipment at the upper limit turn the start ing switch to OFF position A and stop the engine 5 Turn the starting switch to ON po...

Page 385: ...uipment lock lever to LOCK positions 3 Stop the engine 4 Turn the starting switch to ON position B 5 Set the work equipment lock lever to FREE position F 6 Operate the blade control lever and ripper c...

Page 386: ...and aftercooler become dirty and the perform ance lowers or the crankcase pressure increases Never reuse the filter element since it can cause an engine failure After the filter element is replaced i...

Page 387: ...densation of water vapor in the blowby gas However as far as the coolant level is normal it is not a problem 3 Remove used O ring 6 sticking to case 4 and install a new O ring contained in the service...

Page 388: ...t of the body and tighten it with the hand firmly until it stops 7 By using the special wrench further tighten the ring 1 15 to 2 15 turns 1 to 2 ridges of the ring If the engine is operated with the...

Page 389: ...f it is frozen replacement of the filter becomes difficult Replace the filter when the temperature around DEF pump is higher than 11 C and in the condition that DEF is not frozen After the engine is s...

Page 390: ...it out together with filter removal tool 3 If filter 6 cannot be removed from DEF pump grip filter removal tool 3 pull it down then it will be removed 7 Slide filter 6 down and remove spacer 5 from fi...

Page 391: ...ey are likely to wear out or deteriorate Replace them every 2 years or every 4000 hours whichever comes sooner DEFINED LIFE PARTS LIST No Periodical replacement parts Replacement frequency 1 Fuel syst...

Page 392: ...UMULATOR FOR CONTROL CIRCUIT k k WARNING The accumulator is charged with high pressure nitrogen gas so mistaken operation may cause an ex plosion which will lead to serious injury or death or damage F...

Page 393: ...e the accumulator every 2 years or every 4000 hours whichever comes sooner Ask your Komatsu distributor for re placement The accumulator is installed to the position shown in the figure METHOD FOR CHE...

Page 394: ...If there are any problems the related parts must be replaced Ask your Komatsu distributor for replacement MAINTENANCE PROCEDURE MAINTENANCE 4 82...

Page 395: ...amps are installed correctly METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER The fuel spray prevention caps act to prevent the fuel from coming into contact with high tem...

Page 396: ...CE Maintenance for every 250 500 1000 2000 and 4000 hours services should be performed out at the same time METHOD FOR REPLACING ENGINE HIGH PRESSURE PIPING CLAMP Special techniques and tools are requ...

Page 397: ...SPECIFICATIONS 5 1...

Page 398: ...0 ISO 9249 SAE J1349 net 264 1900 A Overall length mm 8405 B Overall height mm 3390 C Overall width mm 4060 Travel speed Forward 1st 2nd 3rd Lo 3rd km h 3 5 5 6 7 5 11 6 Reverse 1st 2nd 3rd Lo 3rd km...

Page 399: ...ATTACHMENTS AND OP TIONS Please read and make sure that you understand the SAFETY section before reading this section 6 1...

Page 400: ...ng or installing an attachment observe the following items and work safely Select a firm level surface when installing or removing an attachment When working in cooperation with one or more other work...

Page 401: ...shoe Wide shoe Heavy duty shoe Heavy duty shoe 610 mm wide 660 mm wide 710 mm wide 610 mm wide 660 mm wide Ripper point Cab with lock Headrest There are many other options in addition to the above Ask...

Page 402: ...g of hard rock beds The rock contact portion of the point is heated to high temperature by friction during ripping and its hard ness decreases The red point is made of material the hardness of which d...

Page 403: ...HANDLE HEADREST Keep the headrest inserted to the end ATTACHMENTS AND OPTIONS HANDLE HEADREST 6 5...

Page 404: ......

Page 405: ...REPLACEMENT PARTS 7 1...

Page 406: ...lamps at the same time as the hoses Also perform the following checks with hydraulic hoses which need not to be replaced periodically Retighten all loose hoses and replace defective hoses as required...

Page 407: ...dge O ring 1 1 Fuel prefilter 600 319 4800 Cartridge assembly 1 Fuel main filter 600 319 3841 Cartridge with cap 1 Every 1000 hours Pilot filter 20Y 62 51691 706 76 71390 Element O ring 1 1 Power trai...

Page 408: ...1 11454 175 71 11530 01643 22245 Cutting edge End bit L H End bit R H Bolt Bolt Nut Washer 48 8 39 39 3 1 1 14 21 35 35 U dozer 175 72 21123 175 70 21126 175 70 21136 175 71 11454 175 71 11463 175 71...

Page 409: ...lt your Komatsu distributor NOTICE The fuel used must be ultra low sulfur diesel fuel 10 ppm To ensure good fuel consumption characteristics and ex haust gas characteristics the engine mounted on this...

Page 410: ...il filter Replace hydraulic oil filter Replace hydraulic tank breather element Replace fuel filter Replace KCCV filter Replace power train oil filter Replace fuel tank breather element Replace power t...

Page 411: ...NAC KES Fuel tank Diesel fuel 30 C 20 C EN 590 0 C 50 C EN 590 DEF tank DEF 30 C 50 C DEF Note 5 Engine oil pan Damper case Power train case Final drive case each of right and left Hydraulic oil syste...

Page 412: ...Amine Engine Coolant AF NAC has excellent anti corrosion antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours Non Amine Engine Coolant AF NAC is strongly recommend...

Page 413: ...thers 2 28 Armrest Adjust 3 162 Ashtray 3 107 Attachments and options 6 3 Auto idle stop timer Set 3 76 Auto switch 3 215 Auto pitch 3 47 Auto pitch pilot lamp 3 35 Automatic operation Start 3 216 Aut...

Page 414: ...ay mode Set 3 82 Display monitor 3 215 Display selector button 3 225 Display setting Change 3 68 Display warning tag during inspection and mainte nance 2 28 Display non display of ECO gauge and drawba...

Page 415: ...uel 4 5 Fuel Check level Add 3 150 Fuel and lubricants 3 234 Fuel and lubricants to match ambient temperature 7 6 Fuel circuit Bleed air 4 42 Fuel consumption gauge 3 40 Fuel consumption gauge Set dis...

Page 416: ...ck bed Dig out 3 193 Leveling work 3 191 Lifting of personnel prohibited 2 16 Link pitch Measure 3 204 Loading and unloading with trailer 3 230 Location of blade serial No plate 1 14 Location of engin...

Page 417: ...3 155 Other equipment 3 105 Other precautions 2 38 Other trouble 3 245 Outer element Clean 4 16 Outline of gear shift mode 3 181 Outline of maintenance 4 5 P Parking brake lever 3 101 Parking brake p...

Page 418: ...en traveling in forward or reverse 2 23 Precautions when traveling on slopes 2 24 3 189 Precautions when using hammer 2 33 Precautions when working on loose ground 2 19 Precautions when working on mac...

Page 419: ...arate 4 25 Track roller Measure diameter 3 205 Track tension Check Adjust 4 23 Transmission system caution lamp 3 21 Transportation 3 229 Trees and stumps Fell Remove 3 192 Troubles and actions 3 239...

Page 420: ...D155AX 8E0 BULLDOZER Form No EENAM03780 2019 KOMATSU All Rights Reserved Printed in Belgium 04 2019...

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