EEAM023402
Operation &
Maintenance Manual
D155AX
BULLDOZER
SERIAL NUMBER
D155AX - 76243
and up
-5
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
FOREWORD
11
FOREWORD FOREWORD
FOREWORD 1
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most acciden ts
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machi nes. Accidents can be prevented by knowing beforehand conditio ns that may cause a haz ard when performing op eration
and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning opera tion or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly
and be sure that you understand them fully.
Keep this manual in the storage location f or the opera tion and ma intenance ma nual given below, and have
all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manua l immediately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your count ry, consult Komatsu or your Komatsu distributor before operating
the machine.
Location to Keep Operation & Maintenance Manual
q Machine equipped with cab
Inside of right and left doors
1-2
FOREWORD FOREWORD
q Machine equipped without cab
Back pocket of operator's seat
1-3
SAFETY INFORMATION FOREWORD
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Signal words
The following signal words are used to inform you that there is a p otential hazardo us situation that may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
DANGER
WARNING
CAUTION
Example of safety message using signal word
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.
WARNING
When standing up from the operator's seat, always place
the lock lever in the LOCK position.
If you accidentally touch the control levers when they are
not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know.
NOTICE
REMARKS
1-4
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
FOREWORD SAFETY INFORMATION
q Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the mach in e th at m ay inv olv e ha za rd .
This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to ind icate safety pro cedures.
Example of safety label using words
Part No.
Safety labels using pictogram
Safety pictograms use a picture to express a level o f hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Part No.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of
your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
1-5
SAFETY INFORMATION FOREWORD
Noise emission levels 1
Two labels indicating the machine noise level are affixed on the machine.
q Sound pressure level at the operator's station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle)
q Sound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.
Vibration levels 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the operator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is less than or equal to 0.5 m/s².
These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
Operating condition:
(WHEEL LOADER:) V-shape loading
(HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating)
1-6
FOREWORD SAFETY INFORMATION
(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion
(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading, and
travelling without load)
Guide to Reduce Vibration Levels on Machine
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine accordin g to this manual
q Tire pressures (for wheeled machines) , tension of crawler (for crawler machines)
q Brake and steering systems
q Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with machine and schedule time to maintain terrain con-
ditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
q Adjust the seat and suspension for the weight and size of the operator
q Wear seat belt
q Inspect and maintain the seat suspension and adjustme nt mec ha nis ms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
q When pushing with bucket or blade, avoid sudden loading; load gradually
q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over rough terrain
q Make the curve radius of traveling path as large as possible
q Travel at low speed when traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance traveling
q Reduce speed to prevent bounce
q Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
q Operate the machine only when you are in good he alt h.
q Provide breaks to reduce long periods of sitting in the same posture
q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads
1-7
INTRODUCTION FOREWORD
INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
q Dozing
q Cutting into hard or frozen ground or ditching
q Felling trees, removing stumps
q Pushing
q Ripping
For further details, see “WORK POSSIBLE USING BULLDOZER (3-118)“ and “RIPPER OPERATION (3-111)“.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1
Front
Left
Operator’s seat
Rear
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
Right
Sprocket
1-8
FOREWORD INTRODUCTION
BREAKING IN THE MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operat ing the machine under full load bef ore breaking the machine in can adversely affect the perf ormance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
q Run the engine at idling for 15 seconds after starting it. During this time, do not operate the control levers or
fuel control dial.
q Idle the engine for 5 minutes after starting it up.
q Avoid operation with heavy loads or at high speeds.
q Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.
1-9
NECESSARY INFORMATION FOREWORD
NECESSARY INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE 1
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 territory.
ENGINE SERIAL NO. PLATE AND POSITION (1) 1
q On the upper of the engine starting motor on the right side of the machine.
q This also acts as the EPA plate.
1-10
FOREWORD NECESSARY INFORMATION
ENGINE SERIAL NO. PLATE AND POSITION (2) 1
q This is the same content as engine serial No. plate (1).
q Located on the top of the air cleaner mounting bracket on the left of the machine.
q This also acts as the EPA plate.
EPA: Environmental Protection Agency, U.S.A.
BLADE SERIAL NO. PLATE POSITION 1
This is located on the upper right of blade back surface.
1-11
NECESSARY INFORMATION FOREWORD
RIPPER SERIAL NO. PLATE POSITION 1
This is located on the left side surface of ripper beam.
ROPS, FOPS NO. PLATE POSITION 1
This is located on the top left.
FOPS
ROPS
POSITION OF SERVICE METER 1
On top of the machine monitor
1-12
FOREWORD NECESSARY INFORMATION
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Product Identification Number
Manufacturers name:
Address:
Distributor
Address
Phone
Service personnel for your
machine:
KOMATSU LTD.
3-6 Akasaka
Minato-ku, 101 Tokyo
Japan
MACHINE SERIAL NUMBER PLATE
Seriel Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manufacturer
Model
1-13
NECESSARY INFORMATION FOREWORD
1-14
FOREWORD NECESSARY INFORMATION
1-15
CONTENTS
CONTENTS
FOREWORD
FOREWORD.........................................................................................................................................................1-2
SAFETY INFORMATION......................................................................................................................................1-4
Noise emission levels ............................................... ... .... ... ... ... .... ...................................... ........................1-6
Vibration levels............................................................................................................................................1-6
Guide to Reduce Vibration Levels on Machine..................................................................................1-7
INTRODUCTION................................................................................................................................................... 1-8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....................................................................... 1-8
BREAKING IN THE MACHINE...................................................................................................................1-9
NECESSARY INFORMATION ...........................................................................................................................1-10
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE.....................................1-10
ENGINE SERIAL NO. PLATE AND POSITION (1) ............................... .... ... ............................................1-10
ENGINE SERIAL NO. PLATE AND POSITION (2) ............................... .... ... ............................................1-11
BLADE SERIAL NO. PLATE POSITION .................................................................................................. 1-11
RIPPER SERIAL NO. PLATE POSITION............................................................................... ..................1-12
ROPS, FOPS NO. PLATE POSITION ...................................................................................................... 1-12
POSITION OF SERVICE METER .......................................................................................................... .. 1-12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................1-13
MACHINE SERIAL NUMBER PLATE . ... ... ... .... ... ... ... ... ....................................... ... .... ... ... ... .... ... ... ... ... ...... 1-13
SAFETY
SAFETY................................................................................................................................................................2-2
SAFETY LABELS.................................................................................................................................................2-4
POSITIONS OF SAFETY PICTOGRAMS ..................................................................................................2-4
SAFETY LABELS .................................. ... ... .... ...................................... .... ................................................. 2-5
GENERAL PRECAUTIONS ...............................................................................................................................2-11
PRECAUTIONS FOR OPERATION................................................................................................................... 2-20
BEFORE STARTING ENGINE .............. ... ... .... ... ....................................... ... ... ... ... .... ... ............................2-20
OPERATION.............................................................................................................................................2-22
TRANSPORTATION................................................................................................................................. 2-26
BATTERY .................................................................................................................................................2-27
TOWING ................................................................................................................................................... 2-29
PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-30
1-16
CONTENTS
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE................................................................................................................. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-5
FRONT PANEL........................................................................................................................................... 3-5
CHECK MONITOR GROUP......................................................... ... ... ... .... ... ... ... .... ........................... 3-7
CAUTION MONITOR GROUP .......................................................................................................... 3-9
EMERGENCY CAUTION ITEMS .................................................................................................... 3-11
METER GROUP.... ... ... ... .... ... ... ....................................... ... ... .... ...................................... ... .......... ... 3-14
SWITCHES...................................................................................................................................... 3-18
LAMPS............................................................................................................................................. 3-21
METHOD OF USING DISPLAY PANEL B (Multi-information) ........................................................ 3-23
SWITCHES............................................................................................................................................... 3-32
CONTROL LEVERS, PEDALS................................................................................................................. 3-37
DUST INDICATOR ................................................................................................................................... 3-44
POWER SOURCE.......................................................................... .... ... ... ... ... .... ... ... ................................ 3-44
FUSE BOX.. .... ... ... ... ... .... ...................................... .... ... ... ....................................... ... ... ............................. 3-45
CIRCUIT BREAKER........................................................................................................................3-47
CIRCUIT BREAKER FOR MAIN POWER SUPPLY........................................................................ 3-47
FUSE CAPACITY AND NAME OF CIRCUIT................................................................................... 3-48
DOOR POCKET ....................................................................................................................................... 3-49
ASHTRAY................................................................................................................................................. 3-49
CAR RADIO, HANDLING ......................................................................................................................... 3-50
EXPLANATION OF COMPONENTS............................................................................................... 3-50
METHOD OF USE........................................................................................................................... 3-52
PRECAUTIONS WHEN USING ...................................................................................................... 3-54
CAR STEREO, HANDLING...................................................................................................................... 3-55
EXPLANATION OF COMPONENTS............................................................................................... 3-55
METHOD OF OPERATION.............................................................................................................3-58
PRECAUTION WHEN USING......................... ... ... ... .... ...................................... .... ... ... ... ... .... ... ... ... 3-60
AIR CONDITIONER.................................................................................................................................. 3-61
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ....................... ... ... ... ... .... ... ... ... 3-61
METHOD OF OPERATION.............................................................................................................3-63
PRECAUTIONS WHEN USING ...................................................................................................... 3-64
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE.......... 3-64
CHECKS DURING OFF-SEASON.................................................................................................. 3-64
PROCEDURE FOR REPLACING RECEIVER................................................................................ 3-65
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................ 3-65
CLEANING AIR FILTER.................................................................................................................. 3-65
SKILLFUL USE OF AIR-CONDITIONER ........................................................................................ 3-66
HEATER, HANDLING............................................................................................................................... 3-67
METHOD OF OPERATION.............................................................................................................3-67
CLEANING AIR FILTER.................................................................................................................. 3-67
ACCUMULATOR, HANDLING.................................................................................................................. 3-68
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH
1-17
CONTENTS
ACCUMULATOR............................................................................................................................. 3-68
OPERATION.......................................................................................................................................................3-69
CHECK BEFORE STARTING ENGINE, ADJUST................................. .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 3-69
WALK-AROUND CHECK ................................................................................................................3-69
CHECK BEFORE STARTING ......................................................................................................... 3-71
ADJUSTMENT.................................................................................................................................3-82
OPERATIONS AND CHECKS BEFORE STARTING ENGINE....................................................... 3-86
STARTING ENGINE................................................................................................................................. 3-88
NORMAL STARTING ............ .... ... ... ... .... ... ... ... ....................................... ... ... .... ...............................3-88
STARTING IN COLD WEATHER.................................................................................................... 3-90
OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................................3-93
WARMING UP OPERATIONS ............................................................................ ... ... .... ... ... ... ... .... .. 3-93
IN COLD AREAS.......................................................... ... .... ... ... ... .... ... ... ......................................... 3-94
STOPPING ENGINE . ... ... ... ....................................... ... .... ... ....................................... ... ... ... ......................3-95
MOVING MACHINE.................................................................................................................................. 3-96
STOPPING MACHINE..................................... ... ... ... ....................................... ... ... .... ...............................3-98
SHIFTING GEAR...................................................................................................................................... 3-99
SHIFTING BETWEEN FORWARD AND REVERSE ..............................................................................3-102
STEERING MACHINE............................................................................................................................ 3-104
NORMAL TURNING............................................................................... ... .................................... 3-104
TURNING WHILE DESCENDING A SLOPE............................. ... .... ......................................... .... 3-105
PRECAUTIONS FOR OPERATION .......................................................................................................3-106
PAY ATTENTION TO GAUGES....................................................................................................3-106
PERMISSIBLE WATER DEPTH.................................................................................................... 3-106
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS........................................................3-106
PRECAUTIONS ON SLOPE ......................................................................................................... 3-107
METHOD OF USING BRAKES ..................................................................................................... 3-107
PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS .........................................3-107
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-107
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY.....................3-108
PARKING MACHINE ............. ... ... ....................................... ... ....................................... ... .......................3-108
CHECK AFTER STOPPING ENGINE ....................................................................................................3-109
CHECK AFTER FINISHING WORK ............ .... ... ... ... ... .... ...................................... .... ... ... ... .... ... ... ... ... .... 3-110
LOCKING................................................................................................................................................3-110
RIPPER OPERATION ............................................................................................................................3-111
EFFECTIVE METHOD OF USE.................................................................................................... 3-111
DIGGING UP BOULDERS OR ROCKBED ................................................................................... 3-111
OPERATING ON SLOPES............................................................................................................ 3-112
METHOD OF OPERATING PIN PULLER.....................................................................................3-112
OPERATING METHOD FOR RIPPING OPERATIONS ......................................................................... 3-113
BASIC OPERATING METHOD ..................................................................................................... 3-11
RIPPING BY CLIFFS..................................................................................................................... 3-114
RIPPING BY SLOPE FACES ........................................................................................................3-114
DIGGING UP BOULDERS ............................................................................................................3-115
PRECAUTIONS WHEN RIPPING.................................................................................................3-116
WORK POSSIBLE USING BULLDOZER ............................................................................................... 3-118
3
1-18
CONTENTS
DOZING......................................................................................................................................... 3-118
SMOOTHING................................................................................................................................. 3-118
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING.................................................. 3-119
FELLING TREES, REMOVING STUMPS..................................................................................... 3-119
PUSHER OPERATIONS.............................................................................. ... ... .... ... ... ... .............. 3-119
ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................. 3-120
METHOD OF ANGLING BLADE................................................................................................... 3-120
ADJUSTING TILT AMOUNT . ....................................... ... ... ... .... ...................................... ... .... ... .... 3-122
ADJUSTING RIPPER...................................................................... ... ... .... .................................... 3-124
ADJUST ANGLE OF BLADE EDGE.............................................................................................. 3-125
TIPS FOR LONGER UNDERCARRIAGE LIFE........................................................................ ... .... ... ... . 3-126
OPERATION METHOD................................................................................................................. 3-126
INSPECTION AND ADJUSTING................................................................................................... 3-127
INSPECTION AND REPAIR .......................................................................................................... 3-128
TRANSPORTATION......................................................................................................................................... 3-130
LOADING, UNLOADING WORK.................................... ... .... ... ... ... .... ... ... ....................................... ....... 3-130
PRECAUTIONS FOR LOADING................................. ... ... .... ... ....................................... ... ... ... ... .... ....... 3-130
METHOD OF LIFTING MACHINE.......................................................................................................... 3-131
PRECAUTIONS FOR TRANSPORTATION ............................. ... ... .... ... ... ... ... .... ... ... ... .... ....................... 3-132
TRAVELING ON ROADS ........ .... ... ... ... .... ... ... ....................................... ... ... ... .... ... ... ... ........................... 3-132
REMOVAL OF CAB................................................................................................................................ 3-133
COLD WEATHER OPERATION...................................................................................................................... 3-135
PRECAUTIONS FOR LOW TEMPERATURE................................................................. ... ... ... ... .... ... ... . 3-135
FUEL AND LUBRICANTS .............................................................................................................3-135
COOLANT ..................................................................................................................................... 3-135
BATTERY...................................................................................................................................... 3-136
AFTER COMPLETION OF WORK......................................................................................................... 3-136
AFTER COLD WEATHER...................................................................................................................... 3-137
LONG-TERM STORAGE..................................................................................................................................3-138
BEFORE STORAGE............................................................................................................................... 3-138
DURING STORAGE............................................................................................................................... 3-138
AFTER STORAGE.................................................................................................................................. 3-138
TROUBLESHOOTING...................................................................................................................................... 3-139
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-139
PROCEDURE FOR BLEEDING AIR............................................................................................. 3-139
METHOD OF TOWING MACHINE.........................................................................................................3-141
IF BATTERY IS DISCHARGED.............................................................................................................. 3-142
REMOVAL AND INSTALLATION OF BATTERY .......................................................................... 3-142
PRECAUTIONS WHEN CHARGING BATTERY........................................................................... 3-143
STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-143
OTHER TROUBLE ................................................................................................................................. 3-146
ELECTRICAL SYSTEM................................................................................................................. 3-146
MONITOR PANEL.........................................................................................................................3-147
CHASSIS........................................................................................................................
............... 3-148
ENGINE......................................................................................................................................... 3-149
1-19
CONTENTS
MAINTENANCE
GUIDES TO MAINTENANCE...............................................................................................................................4-2
OUTLINES OF SERVICE ..................................................................................................................................... 4-5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................4-5
OIL.....................................................................................................................................................4-5
FUEL..................................................................................................................................................4-6
COOLANT AND WATER FOR DILUTION.........................................................................................4-6
GREASE............................................................................................................................................4-6
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ....................................................................4-7
STORING OIL AND FUEL..... ....................................... ... .... ... ....................................... ... ... ... ... ........ 4-8
FILTERS............................................................................................................................................4-8
OUTLINE OF ELECTRIC SYSTEM............................................................................................................ 4-8
HANDLING HYDRAULIC RELATED EQUIPMENT.................................................................................... 4-9
WEAR PARTS LIST ........................................................................................................................................... 4-10
WEAR PARTS LIST..................................................................................................................................4-11
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .................................................................................4-12
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............4-13
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
GENUINE OIL.............................................. .... ... ... ....................................... ... ... ... ...................................4-14
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....................................................................4-15
TORQUE LIST.......................................................................................................................................... 4-15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-16
SAFETY CRITICAL PARTS................................... ... ... ....................................... ... .... ... ... ... .... ..................4-16
MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-18
MAINTENANCE SCHEDULE CHART......................................................................................................4-18
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) .................................... 4-18
WHEN REQUIRED.......................................................................................................................... 4-18
CHECK BEFORE STARTING ......................................................................................................... 4-18
EVERY 250 HOURS SERVICE....................................................................................................... 4-18
EVERY 500 HOURS SERVICE....................................................................................................... 4-19
EVERY 1000 HOURS SERVICE.....................................................................................................4-19
EVERY 2000 HOURS SERVICE.....................................................................................................4-19
EVERY 4000 HOURS SERVICE.....................................................................................................4-19
EVERY 8000 HOURS SERVICE.....................................................................................................4-19
SERVICE PROCEDURE ....................................................................................................................................4-20
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..............................................4-20
WHEN REQUIRED................................................ ... ... ....................................... ... .... ... ............................4-21
CHECK BEFORE STARTING ......................................... ... ... ... .... ... ... ... .... ... ... ......................................... 4-45
EVERY 250 HOURS SERVICE................................................................................................................ 4-46
EVERY 500 HOURS SERVICE................................................................................................................ 4-55
EVERY 1000 HOURS SERVICE..............................................................................................................4-63
EVERY 2000 HOURS SERVICE..............................................................................................................4-71
1-20
CONTENTS
EVERY 4000 HOURS SERVICE................................................................. ............................................. 4-75
EVERY 8000 HOURS SERVICE................................................................. ............................................. 4-78
SPECIFICATIONS
SPECIFICATIONS................................................................................................................................................ 5-2
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS ................................................................................................................................. 6-2
PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2
INTRODUCTION OF ATTACHMENTS AND OPTIONS ...................................................................................... 6-3
INTRODUCTION OF ATTACHMENTS AND OPTIONS............................................................................. 6-3
HEADREST, HANDLING ..................................................................................................................................... 6-4
CAP WITH LOCK, HANDLING............................................................................................................................ 6-5
METHOD OF OPENING AND CLOSING CAP WITH LOCK...................................................................... 6-5
PROCEDURE FOR SELECTING RIPPER POINT............................................................................................... 6-6
PROCEDURE FOR SELECTING RIPPER POINT..................................................................................... 6-6
INDEX
COLOPHON
1-21
CONTENTS
1-22
SAFETY
12
WARNING
Please be sure that you fully underst an d this manual an d the
precautions discribed in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precaustions strictly.
SAFETY SAFETY
SAFETY 2
Safety Labels .. .... ... ... ....................................... ... ... .... ... ... ... ....................................... ... ...................................... 2-42
Positions of Safety Pictograms .................................................................................................................... 2-42
Safety Labels .............................................................................................................................................2-112
General Precautions
Safety Rules............................................................................................................................................... 2-112
If Abnormalities are Found.........................................................................................................................2-112
Clothing and Personal Protective Items..................................................................................................... 2-112
Fire Extinguisher and First Aid Kit..............................................................................................................2-112
Safety Features.......................................................................................................................................... 2-122
Keep Machine Clean..................................................................................................................................2-122
Inside Operator's Compartment.................................................................................................................2-122
Always Apply Lock when Leaving Operator's Seat............................. ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... .......2-132
Handrails and Steps..................................... ... .... ... ... ... ... ....................................... ... .... ... ..........................2-132
Mounting and Dismounting ........................................................................................................................ 2-142
No People on Attachments ........................................................................................................................ 2-142
Prevention of Burns.................................................................................................................................... 2-142
Fire Prevention...........................................................................................................................................2-152
Action if Fire Occurs .. ... ... ... ... .... ... ....................................... ... ... ... .... ... ... ... .................................................2-162
Window Washer Liquid .............................................................................................................................. 2-162
Precautions when Using ROPS ................................................................................................................. 2-162
Precautions for Attachments........ ... ... .... ... ... ... .... ... .................................................................................... 2-172
Unauthorized Modification..........................................................................................................................2-172
Safety at Worksite...................................................................................................................................... 2-172
Working on Loose Ground..................................................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... ....................2-172
Do not Go Close to High-Voltage Cables...................................................................................................2-182
Ensure Good Visibility................................................................................................................................2-182
Ventilation for Enclosed Areas...................................................................................................................2-182
Checking Signalman's Signals and Signs.................................................................................................. 2-192
Be Careful About Asbestos Dust................................................................................................................2-192
2-2
SAFETY SAFETY
Precautions for Operation................................................... ... ... ... .... ... ... ... .... ... ... ..............................................2-202
Before Starting Engine.................................... ... ... ... .... ... ... ... .... ... ... ... ........................................................ 2-202
Checks Before Starting Engine........................................................................................................... 2-202
Precautions when Starting.................................................................................................................. 2-202
Precautions in Cold Areas .................................................................................................................. 2-212
Operation................................................................................................................................................... 2-222
Checks Before Operation.................................................................................................................... 2-222
Precautions for Moving Machine Forward or in Reverse.................................................................... 2-222
Precautions when Traveling................................................................................................................ 2-232
Traveling on Slopes............................................................................................................................ 2-242
Prohibited Operations......................................................................................................................... 2-242
Using Brakes....................................................................................................................................... 2-242
Operate Carefully on Snow................................................................................................................. 2-242
Parking Machine................................................................................................................................. 2-252
Transportation............................................................................................................................................ 2-262
Shipping.............................................................................................................................................. 2-262
Battery........................................................................................................................................................ 2-272
Battery Hazard Prevention.................................................................................................................. 2-272
Starting with Booster Cable ................................................................................................................ 2-282
Towing ....................................................................................................................................................... 2-292
When Towing...................................................................................................................................... 2-292
Precautions for Maintenance ....................... ... .... ... ... ... ... .... .............................................................................. 2-302
Warning Tag .............................................................................................................................................. 2-302
Keep Work Place Clean and Tidy... ... ... .......................................... .......................................... ................. 2-302
Appoint Leader when Working with Others.................. ... ... ... .... ... ... ... .... ... ................................................. 2-302
Stop Engine Before Carrying Out Inspection and Maintenance ................................................................ 2-312
Two Workers for Maintenance when Engine is Running ........................................................................... 2-322
Proper Tools ............ ... ... .... ...................................... .... ... ... ....................................... ... .............................. 2-322
Handling Accumulator................................................................................................................................ 2-332
Personnel................................................................................................................................................... 2-332
Attachments............................................................................................................................................... 2-332
Work Under the Machine ........................................................................................................................... 2-332
Noise........................................................................................................................
Precautions when Using Hammer ............................................................................................................. 2-342
Repair Welding .......................................................................................................................................... 2-342
Removing Battery Terminal ........ .... ... ... ... .... ... ... ... ... .... .......................................... .................................... 2-342
Precautions when Using High-Pressure Grease to Adjust Track Tension................................ ... ... .... ... ... . 2-342
Do not Disassemble Recoil Spring ............................................................................................................ 2-352
Precaution with High-Pressure Oil............................................................................................................. 2-352
Precaution for High Fuel Pressure............................... ... ... ... .... ... .......................................... ... ................. 2-352
Handling High-Pressure Hoses.................................................................................................................. 2-352
Precaution for High Voltage...................................................................... ... ... ... ........................................ 2-362
Waste Material........................................................................................................................................... 2-362
Maintenance for Air Conditioner ................................................................................................................ 2-362
Compressed Air......................................................................................................................................... 2-362
Periodic Replacement of Safety Critical Parts ........................................................................................... 2-362
.................................. 2-342
2-3
SAFETY LABELS SAFETY
SAFETY LABELS 2
POSITIONS OF SAFETY PICTOGRAMS 2
2-4
SAFETY SAFETY LABELS
SAFETY LABELS 2
(1) Precautions for operation, inspection, and maintenance
(09651-A0641)
q Warning!
q Read manual before operation, maintaince, disassembly,
assembly and transportation.
(2) Precautions when traveling in reverse (09802-13000)
WARNING
To prevent SEVERE INJURY or DEATH, do the following
before moving machine or its attachments:
q Honk horn to alert people nearby.
q Be sure no one is on or near the machine.
q Use spotter if view is obstructed.
Follow above even if the machine is equipped with backup alarm and mirrors.
(3) Warning for leaving operator's seat (09654-B0641)
q Sign indicates a hazard of unexpected m oving of stopped
machine.
q Lower working device to ground, move safety lever to lock
position and take engine key with you before leaving
machine.
To prevent SEVERE INJURY or
DEATH, do the following before
moving machine or its attachments
. Honk horn to alert people
nearby.
. Be sure no one is on or near
the machine.
. Use spotter if view is ob-
structed.
Follow above even if the
machine is equipped with
back-up alarm and mirrors.
09802-13000
2-5
SAFETY LABELS SAFETY
(4) Warning for hot water hazard (09653-A0481)
q Never remove the cap when the engine is at operating
(High) temperature. S t re am or h igh temp er ature oil blowin g
up from the radiator or hydraulic tank, will cause personal
injury and / or burns.
q Never remove the radiator or hydraulic tank oil filler when
cooling water or hydraulic oil is at high temperatures.
(5) Precautions when adjusting track tension (09657-A0881)
Safety label is attached to the back side of the inspection
cover of the track frame.
q Sign indicates a hazzard of flying plug from track adjuster
that could cause injury.
q Read the manual and adjusting track for safe and proper
handling.
(6) Precautions for handling accumulator
(09659-A057B)
q There is the hazard of explotion causing injury.
q Do not disassemble the accumulator, make holes in it, weld
it, cut it, hit it, roll it or bring it near flame.
(7) Precautions for use of seat belt
(195-98-12940)
CAUTION
q ALWAYS USE SEAT BELT WHEN OPERATING
MACHINE.
q ALWAYS CHECK CONDITION OF THE SEAT BELT, THE
CONNECTING BRACKETS AND THE TIGHTENING
BOLTS.
q ADJUST SEAT TO ALLOW FULL BREAK PEDAL WITH
OPERATOR’S BACK AGAINST SEAT BACK.
q AFTER ADJUSTING THE HEIGHT, FORE AND AFT
POSITION OF THE SEAT, TIGHTEN THE TETHER BELT
BEFORE SITTING IN THE SEAT.
2-6
SAFETY SAFETY LABELS
(8) Precautions when handling cable
(09808-A0881)
q There is the hazard to electric shock when handling electri c
wires.
q Read the operation and maintenance manual and carrying
out the correct method when handling.
(9) Caution against falling (09805-C0881)
q Sign indicates a hazard of falling
q Do not stand on this place here
(10) Caution to stop engine when carrying out inspection and
maintenance (09667-A0481)
q Sign indicates a hazard of rotating parts, such as belt.
q Turn off before inspection and maintenance.
2-7
SAFETY LABELS SAFETY
(11) Caution about going close when machine is moving
(09806-B1683)
q Sign indicates a hazard of being run over by moving equip-
ment.
q Keep a safe distance from equipment when it is moving.
(12) Caution for high voltage (7872-10-1600)
There is a danger of electrocution.
Turn the starting switch OFF before starting inspection or repairs, and read the operation and maintenance manual
WARNING
Electrical hazard. Switch off the key. Read manual before servicing.
(13) Jump start prohibited (09842-A0481)
q Start the engine only after sitting down in the operator’s
seat.
q Do not attempt to start the engine by short-circuiting the
engine starting circuit. Such an act may cause a serious
bodily injury or fire.
2-8
SAFETY SAFETY LABELS
(14) ROPS (09620-B2000)
1
4
ROPS CERTIFICATION
This protective structure complies with the standard provided that is properly equipped on the machine which
mass is less than the specified maximum mass.
1. MODEL 3. FOPS LEVEL No. 5. MAX. MASS kg (Lb)
2. MACHINE MODEL 4. SERIAL NO.
WARNING
q If some modification is applied to the ROPS. It might not enough strength and might not be complied with the
standard. Consult Komatsu Distributor before altering.
q ROPS may provide less protection if it has been structurally damaged or involved ro ll-over. Consult Komatsu
Distributor in that case.
2
5
3
q Always wear seat belt when moving.
2-9
SAFETY LABELS SAFETY
(15) FOPS (09620-C2000)
1
2
3
4
FOPS CERTIFICATION
This protective structure was provided to comply with the following standard.
1. MODEL 2. MACHINE MODEL
3. SERIAL NO. 4. FOPS LEVEL No.
q If some modification is applied to the FOBS. It might not enough strength and might not be complied with the
standard. Consult Komatsu Distributor before altering.
q FOBS may provide less protection if it has been stru cturally damaged or involved roll-over. Consult Komatsu
Distributor in that case.
q Always wear seat belt when moving.
2-10
SAFETY GENERAL PRECAUTIONS
GENERAL PRECAUTIONS 2
SAFETY RULES
q Only trained and authorized personnel can operate and maintain the machine.
q Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine
may be severly impaired putting yourself and everyone else on your jobsite in danger.
q When working with another operator or with a person on worksite traffic duty, b e sure tha t all per sonn el u nder-
stand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND
If you find any problems in the machine during operation o r mainten ance (noise, vibration, smell, in correct gauges,
smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in
charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
q Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other
protruding parts.
q If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
q Always wear a hard hat and safety sh oes. If the nature of
the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
q Check that all protective equipment functions properly
before using it.
FIRE EXTINGUISHER AND FIRST AID KIT
Always follow the precautions below to prepare for action if any injury or fire should occur.
q Be sure that fire extinguishers have been provided and
read the labels to ensure that you know how to use th em in
emergencies.
q Carry out periodic inspection and maintenance to ensure
that the fire extinguisher can always be used.
q Provide a first aid kit in the storage po int. Carry out peri-
odic checks and add to the contents if necessary.
2-11
GENERAL PRECAUTIONS SAFETY
SAFETY FEATURES
q Be sure that all guards and covers are in their pro per position. Have g uards and covers rep aired immedia tely if
they are damaged.
q Understand the method of use of safety features and use them properly.
q Never remove any safety features. Always keep them in good operating condition.
KEEP MACHINE CLEAN
q If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not
use water or steam to wash the electrical system (sensors, connectors).
q If inspection and maintenance is carried out when the
machine is still dirty with mud or oil, there is a hazard that
you will slip and fall, or that dirt or mud will get into your
eyes. Always keep the machine clean.
INSIDE OPERATOR'S COMPARTMENT
q When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.
If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
q Do not leave parts or tools lying around the operator's compartment.
q Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
q Do not use cellular telephones inside the operator's compar tment when driving or operating the machine.
q Never bring any dangerous objects such as flammable or explosive items into the operator 's compartment.
2-12
SAFETY GENERAL PRECAUTIONS
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT
q Before standing up from the opera tor's se at, lower the work
equipment completely to the ground, set work equipment
lock lever and parking lever securely to the LOCK position,
then stop the engine.
If you accidentally touch the levers when they are not
locked, there is a hazard that the machine may suddenly
move and cause serious injury or property damage.
q When leaving the machine, always lower the work equip-
ment completely to the ground, set work equipment lock
lever and parking lever securely to the LOCK position, then
stop the engine. Use the key to lock all the equipment.
Always remove the key, take it with you, and keep it in the
specified place.
Free
Lock
Free
Lock
HANDRAILS AND STEPS
To prevent personal injury caused by slipping or falling off the machine, always do as follows.
q Use the parts marked by arrow A in the diagrams when
getting on or off the machine.
Never use the parts marked by arrow B when getting on or
off the machine. Use them only when moving along the top
of the track or when checking or carrying out maintenance
inside the side cover, or when filling the tank with oil.
q Never jump on or off the machine. In particular, never get
on or off a moving machine. This may cause serious injury.
2-13
GENERAL PRECAUTIONS SAFETY
q To ensure safety, always face the machine and maintain
three-point contact (both feet and one hand, or both hands
and one foot) with the handrails and steps (including the
track shoe) to ensure that you support yourself.
q Do not grip the control levers, or work equipment lock lever
when getting on or off the machine.
q Never climb on the engine hood or covers where there are
no non-slip pads.
q Before getting on or off the machine, check the handrails
and steps (including the track shoe). If there is any oil,
grease, or mud on the handrails or steps (including the
track shoe), wipe it off immediately. Always keep these
parts clean. Repair any damage and tighten any loose
bolts.
q Do not get on or off the machine while holding tools in your hand.
MOUNTING AND DISMOUNTING
q Never jump on or off the machine. Never get on or off a moving machine.
q If the machine starts to move when ther e is no operator on the machine, d o not jump on to the machine and tr y
to stop it.
NO PEOPLE ON ATTACHMENTS
Never let anyone ride on the work equipment, or other attachments. There is a hazard of falling and suffering serious injury.
PREVENTION OF BURNS
Hot coolant
q To prevent burns from hot water or steam spurting out
when checking or draining the coolant, wait for the water to
cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation. Even when
the coolant has cooled down, loosen the cap slowly to
relieve the pressure inside the radiator before removing the
cap.
Hot oil
q To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to a temperature
where it is possible to touch the cap or plug by hand befor e
starting the operation. Even when the oil has cooled down,
loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.
2-14
SAFETY GENERAL PRECAUTIONS
FIRE PREVENTION
q Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly flammable and can be hazardous. To prevent fire,
always observe the following:
q Do not smoke or use any flame near fuel or oil.
q Stop the engine before refueling.
q Do not leave the machine while adding fuel or oil.
q Tighten all fuel and oil caps securely.
q Do not spill fuel on overheated surfaces or on parts of
the electrical system.
q Use well-ventilated areas for adding or storing oil and
fuel.
q Keep oil and fuel in the determined place and do not
allow unauthorized persons to enter.
q After adding fuel or oil, wipe up any spilled fuel or oil.
q When carrying out grinding or welding work on the
chassis, move any flammable materials to a safe place
before starting.
q When washing parts with oil, use a non-flammable oil.
Diesel oil and gasoline may catch fire, so do not use
them.
q Put greasy rags and other flammable materials into a
safe container to maintain safety at the work place.
q Do not weld or use a cutting torc h to cut any pipes or
tubes that contain flammable liquids.
q Fire coming from accumulated flammable materials
Remove any flammable materials such as dry leaves, chips, pieces of paper, or coal dust accumulated near
the engine exhaust manifold, muffler, or battery.
q Prevention of fire spreading
To prevent fires spreading from sparks or burning particles from other fires, remove any flammable materials
such as dry leaves, chips, or coal dust accumulated around the cooling system (radiator, oil cooler) or inside
the undercover.
q Fire coming from electric wiring
Short circuits in the electrical system can cause fire.
q Always keep electric wiring connections clean and securely tightened.
q Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
2-15
GENERAL PRECAUTIONS SAFETY
q Fire coming from hydraulic line
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to
the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.
q Explosion caused by lighting equipment
q When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-
explosion specifications. If such lighting equipment is not used, ther e is danger of explosion that may
cause serious injury.
q When taking the electrical power for the lighting from th e machine it se lf, follow the instructions in this man-
ual.
ACTION IF FIRE OCCURS
If a fire occurs, escape from the machine as follows.
q Turn the start switch OFF to stop the engine.
q Use the handrails and steps to get off the machine.
WINDOW WASHER LIQUID
Use an ethyl alcohol base washer liquid.
Methyl alcohol base washer liquid may irritate your eyes, so do no t use it.
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)
Install ROPS when working in places where there is danger of
falling rocks, such as in mines and quarries, or in places where
there is danger of rolling over.
q If ROPS is installed, do not remove it when operating the
machine.
q ROPS is installed to protect the operator when machine
rolls over. When machine rolls over, ROPS supports its
weight and absorbs its impact energy.
q If ROPS is modified, its strength may be redu ced. When
modifying, consult your Komatsu distributor.
q If ROPS is deformed by falling objects or by rolling over, its
strength lowers and its design functions cannot be maintained. In this case, be sure to ask your Komatsu distributor about repair method.
Even when the ROPS is installed, if you do not fasten your se at
belt securely, it cannot protect you properly. Always fa sten your
seat belt when operating the machine.
2-16
SAFETY GENERAL PRECAUTIONS
PRECAUTIONS FOR ATTACHMENTS
q When installing optional parts or attachments, there may be problems with safety or legal restrictions. There-
fore contact your Komatsu distributor for advice.
q Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
q When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.
UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
q Komatsu will not be responsible for any injuries, accidents, product failures or other property damages result-
ing from modifications made without authorization from Komatsu.
SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
q When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass,
there is a hazard of fire, so be careful when operating.
q Check the terrain and condition of the ground at the worksite, and determine th e safest method of op eration.
Do not carry out operations at places where there is a hazard of landslides or falling rocks.
q If water lines, gas lines, or high-voltage electrical lines may
be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or damage any
of these lines.
q Take necessary measures to prevent any unauthorized
person from entering the operating ar ea .
q In particular, if you need to operate on a road, protect
pedestrian and cars by designating a person for worksite
traffic duty or by installing fences around the worksite.
q When traveling or operating in shallow water or on soft
ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting
operations.
WORKING ON LOOSE GROUND
q Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collap se under the weight or vibrat ion of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
q When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.
2-17
GENERAL PRECAUTIONS SAFETY
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause
serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as
follows.
q Before starting work near electric cables, inform the local power company of the work to be performed, and
ask them to take the necessary action.
q Even going close to high-voltage cables can cause electric
shock, which may cause serious burns or even death.
Always maintain a safe distance (see the table on the right)
between the machine and the electric cable. Check with
the local power company about safe operating procedure
before starting operations.
q To prepare for any possible emergencies, wear rubber
shoes and gloves. Lay a rubber sheet on top of the seat,
and be careful not to touch the chassis with any exposed
part of your body.
Voltage of Cables Safety Distance
100 V - 200 V Over 2 m
6,600 V Over 2 m
22,000 V Over 3 m
66,000 V Over 4 m
154,000 V Ove r 5 m
187,000 V Ove r 6 m
275,000 V Ove r 7 m
500,000 V Over 11 m
q Use a signalman to give warning if the machine
approaches too close to the electric cables.
q When carrying out operations near high voltage cables, do
not let anyone come close to the machine.
q If the machine should come too close or touch the electric cable, to prevent electric sh ock, the oper ator should
not leave the operator's compartment until it has been confirmed that the electricity has been shut off.
Also, do not let anyone come close to the machine.
ENSURE GOOD VISIBILITY
q Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to
ensure that operations and travel can be carried out safely. Always do as follows.
q Position a signalman if there are areas at the rear of the machine where the visibility is not good.
q When working in dark places , turn on the working lam p and front la mps installed to the machin e, and set
up additional lighting in the work area if necessary.
q Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
VENTILATION FOR ENCLOSED AREAS
Exhaust fumes from the engine can kill.
q If it is necessary to start the engine within an enclosed
area, or when handling fuel, flushing oil, or paint, open the
doors and windows to ensure that adequate ventilation is
provided to prevent gas poisoning.
2-18
SAFETY GENERAL PRECAUTIONS
CHECKING SIGNALMAN'S SIGNALS AND SIGNS
q Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and fo llow the instructions from the signalman.
q Only one signalman should give signals.
q Make sure that all workers understand the meaning of all signals and signs before starting work.
BE CAREFUL ABOUT ASBESTOS DUST
Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsites
handling demolition work or work handling industrial waste.
Always observe the following.
q Spray water to keep down the dust when cleaning. Do not
use compressed air for cleaning.
q If there is danger that there may be asbestos dust in the
air, always operate the machine from an upwind position.
All workers should use an approved respirator.
q Do not allow other persons to approach during the operation.
q Always observe the rules and regulations for the work site and environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always
use genuine Komatsu parts.
2-19
PRECAUTIONS FOR OPERATION SAFETY
PRECAUTIONS FOR OPERATION 2
BEFORE STARTING ENGINE 2
If there is a warning tag hanging from the work equipment control lever, do not start the engine or touch the levers .
CHECKS BEFORE STARTING ENGINE
Carry out the following checks before starting the engine at the beginning of the day's work.
q Completely remove all flammable materials accumulated around the engine and battery, and remove any dirt
from the windows, mirrors, handrails and steps.
q Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and
check for damage to the electric wiring.
q Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no dam-
age or wear to the seat belt or mounting clamps.
q Check that the gauges work properly, check the angle of the lights and working lamps, and check that the con-
trol levers are all in the neutral position.
q Adjust the mirrors so that you can get a good rear-view from the operator's seat.
For the details of adjustment, see “ADJUST MIRROR (3-84)“.
q Check that there are no persons or obstacles above, below, or in the area around the machine.
PRECAUTIONS WHEN STARTING
q When starting the engine, sound the horn as a warning.
q Start and operate the machine only while seated.
q Do not allow anyone apart from the operator to ride on the machine.
q Do not short circuit the starting motor circuit to start the engine. Short circuit can cause fire.
2-20
SAFETY PRECAUTIONS FOR OPERATION
PRECAUTIONS IN COLD AREAS
q Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.
q If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery and cause the battery to explode.
Before charging or starting the engine with a dif ferent p ower source, melt the battery el ectrolyte and check that
there is no leakage of electrolyte before starting.
2-21
PRECAUTIONS FOR OPERATION SAFETY
OPERATION 2
CHECKS BEFORE OPERATION
When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
q Always fasten your seat belt.
q Check the operation of travel, steering and brake systems,
and work equipment control system.
q Check for any problem in the sound of the machine, vibra-
tion, heat, smell, or gauges; check also that there is no
leakage of oil or fuel.
q If any problem is found, carry out repairs immediately.
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE
q Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles.
q Before travelling, sound the horn to warn people in the area.
q Always operate the machine only when seated.
q Do not allow anyone apart from the operator to ride on the machine.
q Check that the back-up alarm (alarm buzzer when machine travels in reverse) works properly.
q Fix the operator's compartment doors and windows in position securely.
Always be sure to carry out the above precautions even when
the machine is equipped with mirrors.
2-22
SAFETY PRECAUTIONS FOR OPERATION
PRECAUTIONS WHEN TRA VELING
q Never turn the starting switch to the OFF position when traveling. It is dangerous if the engine stops when the
machine is traveling. When the engine is off, it is impossible to operate the steering. Apply the brakes and stop
the machine immediately, if the engine stops.
q When traveling on flat ground, keep the work equipment 40 to 50 cm high above the ground.
q When traveling on rough ground, travel at low speed and
do not operate the steering suddenly. There is danger that
the machine may turn over. The work equipment may hit
the ground surface and cause the machine to lose its balance, or may damage the machine or structures in the
area.
q Avoid traveling over obstacles when possible. If the
machine has to travel over an obstacle, keep the work
equipment close to the ground and travel at low speed.
Never travel over obstacles which make the machine tilt
strongly to one side.
q When traveling or carrying out operations, always keep a
safe distance from people, structures, or other machines to
avoid coming into contact with them.
q When passing over bridges or structures, check first that
the structure is strong enough to support the weight of the
machine. When traveling on public roads, check first with
the relevant authorities and follow their instructions.
q When operating in tunnels, under bridge s, under electric wires, or other places where the height is limited,
operate slowly and be extremely careful not to let the work equipment hit anything.
q Do not approach the edge of a cliff carelessly. When dropping soil over a cliff for banking or reclamation, leave
soil of one scoop at the edge of the cliff and push it with the next scoop.
q When the machine passes over the top of a hill or when a load is dumped over a cliff, the load is suddenly
reduced, and there is danger that the travel speed rises suddenly. To prevent this, lower the travel speed.
q If the machine moves with only either side of the blade loaded, its tail may swing. Take care.
2-23
PRECAUTIONS FOR OPERATION SAFETY
TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always do as follows.
q When traveling on slops, keep the blade appr oxmately 20
to 30 cm above the ground. In case of emergency, quickly
lower the blade to the ground to help the machine to stop.
Apply the brake and use the engine as a brake, if necessary.
q Always travel straight up or down a slope. Traveling at an
angle or across the slope is extremely dangerous.
q Do not turn on slopes or travel across slopes. Always go
down to a flat place to change the position of the machine,
then travel on to the slope again.
q Travel on grass, fallen leaves, or wet steel plates with low
speed. Even with slight slopes there is a hazard that the
machine may slip.
q Do not shift the gear while traveling downhill or travel downhill with the transmission in neutral. If this is
neglected, the engine does not work as a brake, and that is dangerous. Be sure to set the transmission in one
of the lower gear speeds. In addition, apply the brake and use the engine as a brake, if necessary.
q When turning on a downhill ground, lower the travel speed.
PROHIBITED OPERATIONS
q To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff
with the sprocket at the rear when carrying out operations.
q When operating the machine, take care that it will not exceed its performance values such as stability, maxi-
mum using load, etc. to prevent rolling of the machine caused by an overload and disasters caused by breakage of the work equipment.
USING BRAKES
q When the machine is traveling, do not rest your foot on the brake pedal. If you travel with your foot resting on
the pedal, the brake will always be applied, and this will cause the brakes to overheat and fail.
q Do not depress the brake pedal repeatedly if not necessary. If this is neglected, the brake will be overheated
and will not work when required.
q When traveling downhill, use the braking force of the engine, and always use the right brake pedal.
OPERATE CAREFULLY ON SNOW
q Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the
machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.
q With frozen ground surfaces, the ground becomes soft when the temperat ure rises, and this may cause the
machine to tip over .
q If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful not to leave the road shoulder or to get trapped in a snow drift.
q When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations carefully.
q When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and use the
engine as a brake while appling the foot brake intermittently (depress the brake in te rmittently several times). If
necessary, lower the blade to the ground to stop the machine.
2-24
SAFETY PRECAUTIONS FOR OPERATION
PARKING MACHINE
q Park the machine on level ground where there is no danger
of falling rocks or landslides, or of flooding if the land is low,
and lower the work equipment to the ground.
q If it is necessary to park the machine on a slope, set the
blocks under the tracks to prevent the machine from moving, then dig the work equipment into the ground.
q After stopping the engine, operate the right work equip-
ment control lever several times to the RAISE and LOWER
positions to release the remaining pressure in the hydr aulic
circuit.
q When parking the machine on a road, put up flags, fences, lighting, or warning signs to enable passing vehi-
cles to recognize the machine clearly. At the same time, make sure that these do not cause obstruction to the
passing vehicles.
Procedure for parking: See “PARKING MACHINE (3-108)“.
q When leaving the machine, set the lock levers (for work equipment and brake) to the LOCK position, and then
stop the engine. In addition, use the key to lock all the equipment. Always remove the key and take it with you
to be kept at a set location.
Work equipment posture: See “PARKING MACHINE (3-108)“
Locks: See “LOCKING (3-110)“
q Always close the door of the operator's compartment.
Thrust the edge
Block
Thrust the edge
2-25
PRECAUTIONS FOR OPERATION SAFETY
TRANSPORTATION 2
The machine can be divided into parts for transpo rtation, so when transportating the machine, please contact your
Komatsu distributor to have the work carried out.
SHIPPING
When shipping the machine on a trailer, do as follows.
q The weight, transportation height, and overall length of the machine differ according to the work equipment, so
be sure to confirm the dimensions.
q When passing over bridges or structures on private land, check first that the structu re is stron g enough to sup-
port the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their instructions.
q For details of the shipping procedure, see “TRANSPORTATION (3-130)“ in the OPERATION section.
2-26
SAFETY PRECAUTIONS FOR OPERATION
BATTERY 2
BATTERY HAZARD PREVENTION
Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.
Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.
q When working with batteries, always wear safety glasses and rubber gloves.
q Never smoke or use any flame near the battery.
q If you spill acid on your clothes or skin, immediately flush
the area with large amount of water.
q If acid gets into your eyes, flush them immediately with
large amount of water and seek medical attention.
q Before working with batteries, turn the starting switch to the OFF position.
As there is a hazard that sparks will be generated, always do as follows.
q Do not let tools or other metal objects make any contact betw een the batter y terminals. Do not le ave tools or
other metal objects lying around near the battery.
q Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals
securely.
q Tighten the battery terminals securely.
q Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
q Tighten the battery caps securely.
q Install the battery securely to the determined place.
2-27
PRECAUTIONS FOR OPERATION SAFETY
STARTING WITH BOOSTER CABLE
If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
q When starting with a booster cable, carry out the starting
operation with two workers (one worker sitting in the operator's seat and the other working with the battery).
q When starting from another machine, do not al low the two
machines to touch.
q When connecting the booster cables, turn the starting
switch OFF for both the normal machine and problem
machine. There is a hazard that the machine will move
when the power is connected.
q Be sure to connect the positive (+) ca ble first when install-
ing the booster cables. Disconnect the negative (-) cable
(ground side) first when removing them.
q When removing the booster cables, be careful not to let the
booster cable clips touch each other or to let the clips touch
the machine.
q Always wear safety goggles and rubber gloves when start-
ing the engine with booster cables.
q When connecting a normal machine to a problem machine
with booster cables, always use a normal machine with the
same battery voltage as the problem machine.
q For details of the procedure when st arting the mach ine using a bo oster cable, se e “STARTING ENGINE WITH
BOOSTER CABLE (3-143)“.
2-28
SAFETY PRECAUTIONS FOR OPERATION
TOWING 2
WHEN TOWING
Injury or death could result if a disabled machine is towed
incorrectly. Always observe the following rules.
q Never use a towing method different from the one
described in this manual.
For the method of towing, see “METHOD OF TOWING
MACHINE (3-141)“.
q When handling a wire rope, always wear leather gloves.
q When working with others to prepare for towing, signals
should be agreed upon beforehand.
q If your machine is towed by another machine, stop the
engine and release the brake. Please contact your
Komatsu distributor to have the brake released.
q Towing on slopes is dangerous. When doing so, choose a
gentle slope. If no gentle slope is available, make such a
slope by earth-removal work.
q When connecting up a towing machine, do not let anyone
enter the area between the towing machine and the equipment being towed.
q Do not straddle the towing cable or wire rope.
q When your machine is towed by another machine,
ALWAYS use a wire rope with a sufficient towing capacity.
q Set the towing machine and the towing connection of the
equipment being towed in a straight line when connecting
it.
q Take up the slack in the wire rope and tow the machine.
q When lifting the machine up, use the towing hook.
q If the machine is stuck in mud, dig around the towing hook, then use the towing hook.
Permitted towing load: 29,300 kg (287,330 N)
q Do not use a broken (A), kinked (B) or frayed (C) wire rope.
2-29
PRECAUTIONS FOR MAINTENANCE SAFETY
PRECAUTIONS FOR MAINTENANCE 2
WARNING TAG
q When carrying out inspection or maintenance, ALWAYS
attach the “DO NOT OPERATE“ warning tag to the blade
control lever in the operator's cab to alert others that you
are working on the machine. Attach additional wa rning t ags
around the machine in necessary.
Warning tag Part No. 09963-A1640
This tag is placed in the same case as is this operation and
maintenace manual.
q If others start the engine, or touch or operate the work
equipment control lever while you are performing service
or maintenance, you could suffer serious injury or property
damage.
KEEP WORK PLACE CLEAN AND TIDY
q Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out operations safely.
If the work place is not kept claen and tidy , there is the danger that you will trip, slip, or fall over and injure yourself.
APPOINT LEADER WHEN WORKING WITH OTHERS
q When repairing the machine or when removing and installing the work equipment, appoint a leader and follow
his instructions during the operation.
2-30
SAFETY PRECAUTIONS FOR MAINTENANCE
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
q Stop the machine on firm, level ground.
q Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
q Lower the work equipment completely to the ground and
stop the engine.
q Operate the blade control lever 2-3 times to the RAISE and
LOWER positions to release the remaining pressure in the
hydraulic circuit, then set work equipment lock lever to the
LOCK position.
Free
Lock
q Put blocks under the track to prevent the machine from
moving.
Free
Lock
Block
2-31
PRECAUTIONS FOR MAINTENANCE SAFETY
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
To prevent injury, do not carry out maintenance with the engine
running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and
do as follows.
q One worker must always sit in the operator's seat and be
ready to stop the engine at any time. All workers must
maintain contact with the other workers.
q Set the work equipment lock lever to the LOCK position to
prevent the machine from moving.
q When carrying out operations near the fan, fan belt, or
other rotating parts, there is a hazard of bein g caught in the
parts, so be careful not to come close.
Free
q Do not touch any control levers. If any control lever must
be operated, give a signal to the other w orkers to warn
them to move to a safe place.
q Never drop or insert tools or other objects into the fan or
fan belt. Parts may break or be sent flying.
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
Lock
Free
Lock
2-32
SAFETY PRECAUTIONS FOR MAINTENANCE
HANDLING ACCUMULATOR
q This machine is equipped with an accumulator. For a short time after the engine is stopped, if the work equip-
ment control lever is moved to the LOWER position, the work equipment will move down under its own weight.
After stopping the engine, always set the work equipment lock lever to the LOCK position.
q When releasing the pressure in the work equipment circuit on machines equipped with an accumulator, carry
out the procedure in accordance with the method for handling the accumulator.
Method of releasing pressure: See “METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON
MACHINE EQUIPPED WITH ACCUMULATOR (3-68)“.
q The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is handled in the
wrong way. Always observe the following precautions.
q Never make any hole in the accumulator or expose it to flame or fire
q Do not weld any boss to the accumulator.
q When disposing of the accumulator, it is necessary to release the gas from the accumulator. A special air
bleed valve is necessary for this operation, please contact your Komatsu distributor.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the
area. If necessary, employ an observer.
ATTACHMENTS
q Appoint a leader before starting removal or installation
operations for attachments.
q Place attachments that have been removed from the
machine in a stable condition so that they do not fall. And
take steps to prevent unauthorized persons from entering
the storage area.
WORK UNDER THE MACHINE
q If it is necessary to go under the work equipment or the
machine to carry out service and maintenance, support the
work equipment and machine securely with blocks and
stands strong enough to support the weight of the work
equipment and machine.
q It is extremely dangerous to work under the machine if the
track shoes are lifted off the ground and the machine is
supported only with the work equipment. If any of the control levers is touched by accident, or there is damage
occurring to the hydraulic piping, the work equipment or th e
machine will suddenly drop. This is extremely dangerous.
Never work under the work equipment or the machine.
2-33
PRECAUTIONS FOR MAINTENANCE SAFETY
NOISE
When carrying out maintenance of the engine and you are expo sed to noise for long peri ods of time, wear ear covers or ear plugs while working.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
PRECAUTIONS WHEN USING HAMMER
When using a hammer, pins may fly out or metal particles may
be scattered. This may lead to serious injury. Always do as
follows.
q If hard metal parts such as pins, bucket teeth, cutting
edges, or bearings are hit with a hammer, there is a hazard
that pieces might be scattered and cause injury. Always
wear safety goggles and gloves.
q When hitting pins or bucket teeth, there is a hazard that
broken pieces might be sent flying and injure people in the
surrounding area. Always check that there is no one in the
surrounding area.
q There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or el ectrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.
REMOVING BA TTERY TERMINAL
When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of
the battery to prevent the flow of current.
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION
q Grease is pumped into the track tension adjustment sys-
tem under high pressure. If the specified procedure for
maintenance is not followed when making adjustment,
grease drain valve (1) may fly out and cause serious injury
or damage.
q When loosening grease drain valve (1) to loosen track ten-
sion, never loosen it more than one turn. In doing so,
loosen the valve slowly.
q Never put your face, hands, feet, or any other part of your
body directly in front of grease drain valve (1).
2-34
SAFETY PRECAUTIONS FOR MAINTENANCE
DO NOT DISASSEMBLE RECOIL SPRING
Never attempt to disassemble the recoils spring assembly. It contains a spring under high pressure which serves
as a shock absorber for the idler. If it is disassembled by mistake, the spring will fly out and cause serious injury.
When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work.
PRECAUTION WITH HIGH-PRESSURE OIL
The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury, so always do as follows.
q Release the pressure. For details, see “PROCEDURE FOR RELEASING INTERNAL PRESSURE IN
HYDRAULIC CIRCUIT (4-44)“. Do not carry out inspection or replacement while the circuit is still under pressure.
q If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the
piping and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
q There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it contacts your eyes directly. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the
place with clean water, and consult a doctor immediately
for medical attention.
PRECAUTION FOR HIGH FUEL PRESSURE
High pressure is generated inside the engine fuel piping whe n the engine is r unning. When carrying out inspe ction
or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before starting inspection or maintenance.
HANDLING HIGH-PRESSURE HOSES
q If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torqu e. If any damaged hoses are
found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
q Damaged or leaking hydraulic fitting.
q Frayed or cut covering or exposed reinforcement wire layer.
q Covering swollen in places.
q Twisted or crushed movable portion.
q Foreign material embedded in covering.
2-35
PRECAUTIONS FOR MAINTENANCE SAFETY
PRECAUTION FOR HIGH VOLTAGE
q When the engine is running and immediately after it is
stopped, high voltage is generated inside the engine controller and the engine injector, and there is danger of electrocution. Never touch the inside of the controller or the
engine injector portion.
If it is necessary to touch the inside of the controller or the
engine injector portion, please contact your Komatsu distributor.
WASTE MATERIAL
To prevent pollution, pay careful attention to the method of disposing of waste materials.
q Always put oil drained from your machine in containers.
Never drain oil directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
q Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
and batteries.
MAINTENANCE FOR AIR CONDITIONER
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite.
Never touch refrigerant.
COMPRESSED AIR
q When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
q When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
q In order for the machine to be operated safety for a long time, it is necessary to add oil and to carry out service
and maintenance at periodic intervals. In order to further increase safety, components with a strong relationship to safety , such as hoses and seat belts, must be replaced at periodic intervals.
Replacement of safety critical parts: See “PERIOD IC REPLACEMENT OF SAFETY CRITICAL PARTS (4-
16)“.
q The material of these components naturally changes over time, an d repe ated u se causes deterioration, wear,
and fatigue. As a result, there is a hazard that th ese components may fail and cause serious 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 specified interval.
q Replace or repair safety-critical parts if any defect is found, even when they have not reached the time speci-
fied interval.
2-36
OPERATION
13
WARNING
Please read and make sure that you understand the SAFETY
section before reading this section.
GENERAL VIEW OPERATION
GENERAL VIEW 3
GENERAL VIEW OF MACHINE 3
(1) Blade (7) Multi ripper
(2) Blade tilt cylinder (8) Ripper lift cylinder
(3) Blade lift cylinder (9) Sprocket
(4) Cab (10) Track frame
(5) Track shoe (11) Frame
(6) Ripper tilt cylinder (12) Idler
3-2
OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES 3
(1) Parking lever (11) Starting switch
(2) Work equipment lock lever (12) Information switch
(3) Cigarette lighter (13) Buzzer cancel switch
(4) Fuel control dial (14) Brake pedal
(5) Joystick (Steering, directional and gear shift
lever)
(6) Auto shift down switch (17) Horn switch
(7) Front lamp switch (18) Ripper control lever
(8) Air conditioner panel or heater pan el(speed
range display, engine speed)
(9) Rear lamp switch (21) Wiper switch
(10) Fan rotation selector switch (22) Room lamp sw itch
(15) Deceleration pedal
(16) Blade control lever
(19) Ripper control lever
(20) Pin puller control switch (if equipped)
3-3
GENERAL VIEW OPERATION
FRONT PANEL
(1) Engine coolant temperature gauge (10) Engine pre-heating pilot lamp
(2) Power train oil temperature gauge (1 1 ) Maintenance caution lamp
(3) Hydraulic oil temperature gauge (12) Warning lampFilter/oil change interval lamp
(4) Fuel level gauge (13) Filter/oil change interval lamp
(5) Charge level caution lamp
(6) Engine oil pressure caution lamp
(14) Display panel A (speed range display, engine
speed)
(7) Engine coolant temperature caution lamp (15) Display panel B (multi-information)
(8) Power train oil temperature caution lamp (16) Fan operation confirmation lamp
(9) Hydraulic oil temperature caution lamp (17) HSS charge pressure caution lamp
HSS: Hydro Static Steering System
3-4
OPERATION EXPLANATION OF COMPONENTS
EXPLANATION OF COMPONENTS 3
The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
FRONT PANEL 3
A: Check monitor group D: Meter group
B: Caution monitor group E: Switches
C: Emergency caution items F: Lamps
A: Check monitor group (see “CHECK MONITOR GROUP (3-7)“)
Before the engine is started, the basic items am ong the check before starting ite ms that m us t be chec ked are dis played.
If there is any abnormality, the caution lamp for the location of the abnormality flashes.
NOTICE
When performing the check before starting, do not rely only on these monitors. Always perform the
inspection items according to the maintenance section or Section “OPERATION (3-69)“.
3-5
EXPLANATION OF COMPONENTS OPERATION
B: Caution monitor group (see “CAUTION MONITOR GROUP (3-9)“ )
CAUTION
If the caution lamp for any of these items flashes, check and repair the appropriate item as soon as possible.
These are items, which need to be observed while the engine is running. If any abnormality occurs, items, which
need to be repaired as soon as possible, are displayed.
If there is any abnormality, the appropriate monitor lamp will flash to indicate the location of the abnormality.
C: Emergency caution items (see “EMERGENCY CAUTION ITEMS (3-11)“)
CAUTION
If the caution lamp for any of these items flashes, stop the engine immediately or run it at low idling, and
take the following action.
This displays the abnormal items that action must be taken on immediately the engine is running.
If there is any abnormality, the monitor showing the location of the abnormality will flash and the alarm buzzer will
sound.
D: Meter group (see “METER GROUP (3-14)“)
This consists of the preheating pilot lamp, power train oil temperature gauge, engine water temperature gauge,
hydraulic oil temperature gauge, fuel gau ge, display panel A (speed range disp lay) and display panel B (multiinformation).
E: Switches (see “SWITCHES (3-32)“)
This consists of the starting switch, buzzer cancel switch, front lamp switch, rear lamp switch, automatic shift down
switch, information switch, and fan rotation selector switch.
F: Lamps (see “LAMPS (3-21)“)
This consists of the warning lamp, the filter/oil replacement interval lamp, and fan operation confirmation lamp.
3-6
OPERATION EXPLANATION OF COMPONENTS
CHECK MONITOR GROUP 3
NOTICE
q When performing the check before starting, do not rely only on these monitors. Always refer to
“OPERATION (3-69)“ to perform these checks.
q Park the machine on level ground and then check the monitor lamps.
q Confirm that monitor lamps light u p about 2 se con ds after the starting switch is turned to the ON pos i-
tion. If any monitor lamp does not light, contact your Komatsu distributor to inspect and repair.
REMARK
When the starting switch is turned to the ON position, before starting the engine, the caution lamps flash for 2 seconds, the warning lamps light up for 2 seconds, and the alarm buzzer sounds for 2 seconds.
The caution lamps cannot be checked for any malfunction until at least 5 seconds after the engine has been
stopped.
This displays the basic items among the check befo re starting items that must be checked before starting the
engine. If there is any abnormality, the caution lamp for that location will flash.
A(1) Maintenance caution lamp
3-7
EXPLANATION OF COMPONENTS OPERATION
MAINTENANCE CAUTION LAMP
This lamp (1) flashes when the time for changing the filter or oil
has been exceeded. “DISPLAY PANEL B (Multi-information)
(3-16)“ to the maintenance mode, and check or replace the
appropriate filter or oil.
3-8
OPERATION EXPLANATION OF COMPONENTS
CAUTION MONITOR GROUP 3
CAUTION
If these caution lamps flash, check and repair the appropriate location as soon as possible.
NOTICE
q Park the machine on level ground and check the monitor lamps.
q Confirm that monitor lamps light u p about 2 se con ds after the starting switch is turned to the ON pos i-
tion. If any monitor lamp does not light, contact your Komatsu distributor to inspect and repair.
These are items which need to be observed when the engine is runni ng. If any proble m occurs, the ite m needing
immediate repair is displayed. If there is any problem, the problem location on the caution lamp will flash.
B(1) Charge level caution lamp
3-9
EXPLANATION OF COMPONENTS OPERATION
CHARGE LEVEL CAUTION LAMP
Lamp (1) indicates an abnormality in the charging system while
the engine is running.
If the monitor lamp flashes, check the V-belt tension. If any
abnormality is found, see “OTHER TROUBLE (3-146)“.
REMARK
This monitor lamp lights when the starting switch is turned to
ON immediately after the engine is started or immediately
before the engine is stopped. It does not indicate an problem.
3-10
OPERATION EXPLANATION OF COMPONENTS
EMERGENCY CAUTION ITEMS 3
CAUTION
If the caution lamp for any of these items flashes, stop the engine immediately or run it at low idling, and
take the following action.
NOTICE
q Park the machine on level ground and check the monitor lamps.
q Confirm that these caution lamps light for about 2 seconds after the starting switch is turned to ON. If
any monitor lamp does not light, have your Komatsu distributor inspect and repair it.
These items need to be observed while the engine is running. If an y abnormality occurs, items that need to be
repaired immediately are displayed.
If there is any abnormality, alarm buzzer sounds intermittently and the abnormal location on the caution lamp will
flash.
C (1) Engine oil pressure caution lamp C (4) Hydraulic oil temperature caution lamp
C (2) Engine coolant temperature caution lamp C (5) HSS charge pressure caution lamp
C (3) Power train oil temperature caution lamp
3-11
EXPLANATION OF COMPONENTS OPERATION
ENGINE OIL PRESSURE CAUTION LAMP
This lamp (1) indicates low engine oil pressure.
If the monitor lamp flashes, stop the engine and check it immediately.
REMARK
The alarm buzzer sounds, when the starting switch is turned to
ON immediately after the engine oil has been changed. It does
not indicate an problem.
ENGINE COOLANT TEMPERATURE CAUTION LAMP
This lamp (2) indicates a rise in the coolant temperature.
When the monitor lamp flashes, run the engine at low idling
speed until green range of the engine coolant temperature
gauge lights.
POWER TRAIN OIL TEMPERATURE CAUTION LAMP
This lamp (3) indicates a rise in the oil temperature of the
torque converter outlet.
When the monitor lamp flashes, run the engine at the lo w idling
speed until the green range of the power train oil temperature
gauge lights.
HYDRAULIC OIL TEMPERATURE CAUTION LAMP
Lamp (4) indicates a rise in the hydraulic oil temperature.
When the monitor lamp flashes, stop the machine and run the
engine at the low idling speed until oil temperature falls.
3-12
OPERATION EXPLANATION OF COMPONENTS
HSS CHARGE PRESSURE CAUTION LAMP
This monitor (5) warns the operator that the HSS charge pressure has dropped. If it flashes, stop the engine and carry out
inspection.
REMARK
The buzzer may sound when the starting switch is turned ON
or immediately after the engine is started, b ut this does not indicate any abnormality .
3-13
EXPLANATION OF COMPONENTS OPERATION
METER GROUP 3
NOTICE
When the engine is stopped, turn that the starting switch to the ON position and check that the gauge or
monitor for the engine water temperature gauge, power train oil temperature gauge, and fuel gauge light
up.
If they do not light up, please contact your Komatsu distributor for repairs.
D (1) Engine coolant temperature gauge D (5) Engine pre-heating pilot lamp
D (2) Power train oil temperature gauge
D (3) Hydraulic oil temperature gauge
D (4) Fuel level gauge D (7) Display panel B (multi-information)
ENGINE COOLANT TEMPERATURE GAUGE
Gauge (1) indicates temperature of the engine coolant.
If the temperature is normal during operation, green range (B)
will light.
If red range (C) lights during operation, move the fuel control
dial to lower engine speed to approx. 3/4 of the full speed, and
run until the coolant temperature enters green range (B).
During operation, if red range (C) lights up, the engine coolant
temperature monitor flashes, and the alarm buzzer sounds,
stop the machine, run the engine at low idling, and wait for the
coolant temperature to go down to green range (B) .
(A): White range
(B): Green range
(C): Red range
NOTICE
If the coolant temperature gauge often enters red range (C), check the radiator for clogging.
D (6) Display panel A
(Speed range display, engine speed)
3-14
OPERATION EXPLANATION OF COMPONENTS
POWER TRAIN OIL TEMPERATURE GAUGE
Gauge (2) indicates the torque converter outlet oil temperature.
If the temperature is normal during operation , green range ( B)
will light.
If red range (C) lights up during operation, move the fuel control dial to lower engine speed to approx. 3/4 of the full speed,
reduce the load and run until the oil temperat ure enters green
range (B).
If red range (C) lights up, the power train oil temperature caution lamp flashes, and the alarm buzzer sounds during operation, stop the machine, run at low idling, and wait for the oil
temperature to go down to green range (B).
(A): White range
(B): Green range
(C): Red range
NOTICE
In cases where the power train oil temperature gauge te nds to enter red ra nge (C), we recommend t hat you
lower the speed range by one range in order to reduce the load on the power train during oper ations.
HYDRAULIC OIL TEMPERATURE GAUGE
Gauge (3) indicates the hydraulic oil temperature.
If the temperature is normal during operation , green range ( B)
will light.
If the red range (C) lights up during operation, move the fuel
control lever to lower the engine speed to approx. 3/4 o f the full
speed, reduce the load and run until the oil temperature enters
the green range (B).
(A): White range
(B): Green range
(C): Red range
FUEL LEVEL GAUGE
Gauge (4) fuel level in the fuel tank.
During normal operation, the green range (B) should be lit.
If red range (A) lights up during operation, add fuel immediately. If this is not do ne, the engine speed will be come irrgular
or an error display will be shown on the monitor.
(A): Red range
(B): Green range
REMARK
The display is not proportional to the amount of fuel remaining.
If only the red range (A) lights up, there is less than 60 liters of
fuel remaining.
3-15
EXPLANATION OF COMPONENTS OPERATION
ENGINE PRE-HEATING PILOT LAMP
Lamp (5) indicates that engine is being pre-heated by the electrical heater during cold weather.
The engine controller detects the coolant temperature and
automatically actuates pre-heating in low temperatures when
starting the engine.
DISPLAY PANEL A (speed range display, engine speed)
Meter (6) displays the transmission speed range being used on
the machine and engine speed.
Engine speed
Speed range
q When the transmission is in 1st FORWARD, the display
shows F1, and when it is in 1st REVERSE, the display
shows R1.
q The peripheral bar graph indicates the engine speed.
When the red range lights up during running, shift the gear
to a lower speed to run the engine at a speed within the
Red
green range.
DISPLAY PANEL B (Multi-information)
This monitor (7) displays information related to the condition of
the machine on the top and bottom lines of the display port ion.
The content of the display can be switched by operating the
Information switch and Buzzer cancel switch.
(1) Operating mode (normal operation screen)
Use this mode when operating the machine.
REMARK
When the starting switch is turned from the OFF to the ON
position, the multi-information display changes to the operating
mode.
The bottom right of the monitor displays the total hours of operation of the machine. Use this service meter function display to set the intervals for periodic maintenance.
When the engine is running, the service meter advances, even if the machine is not be ing operated.
When the engine is running, the operation display of the hourglass mark on the side of the meter lights up to show
that the meter is advancing.
The meter advances by 1 for one hour of engine operation, regardless of the engine speed.
The failure code is also displayed on the top line if there is a failure on the machine. If it is displayed, follow the
action given in “OTHER TROUBLE (3-146)“.
3-16
OPERATION EXPLANATION OF COMPONENTS
(2) Maintenance mode
The maintenance mode is displayed by continuing to turn the
information switch in the direction for 2.5 seconds.
For details, see “METHOD OF USING DISPLAY PANEL B
(Multi-information) (3-23)“.
3-17
EXPLANATION OF COMPONENTS OPERATION
SWITCHES 3
E (1) Starting switch E (5) Rear lamp switch
E (2) Buzzer cancel switch E (6) Fan rotation selector switch
E (3) Information switch E (7) Auto shift down switch
E (4) Front lamp switch
STARTING SWITCH
Switch (1) is used to start the engine.
OFF
Key insertion-withdrawal position. None of electrical circuits
activate.
ON
Charging and electric device circuits activate. Keep key in the
ON position after starting.
START
In this key position, the starting motor will crank the engine.
Immediately after starting the engine, release the key which will
automatically return to the ON position.
3-18
OPERATION EXPLANATION OF COMPONENTS
BUZZER CANCEL SWITCH
When this switch (2) is turned to the right, the alarm buzzer
stops. When the information monitor is in the maintenance
mode, this switch is used to select the mode item.
Position (a): Cancel
Position (b): Select
INFORMATION SWITCH
This switch (3) is used to switch the display mode item on the
information monitor and to move the cursor in the maintenance
mode.
Position (a): Cursor moves to left, mode item display goes back
to previous item.
Position (b): Cursor moves to right, mode item display
advances to next item.
FRONT LAMP SWITCH
This switch (4) is used to light up the front lamp.
Position (a) (OFF): Lamp goes out
Position (b) (ON): Lamp lights up
REMARK
When the head lamp switch is turned ON, the monitor panel
lighting dims.
REAR LAMP SWITCH
This switch (5) is used to turn on the rear lamp.
Position (a) (OFF): Lamp goes out
Position (b) (ON): Lamp lights up
3-19
EXPLANATION OF COMPONENTS OPERATION
FAN ROTATION SELECTOR SWITCH
This switch (6) is used to switch the fan to the reverse mode
and clean mode.
Position (a): Normal mode
Position (b): Reverse mode
Position (c): Clean mode
q Use the reverse mode in cold weather to maintain the tem-
perature and use the clean mode when removing dirt and
foreign material clogging the radiator. In the clean mode,
the fan always rotates at 100% speed.
q When operating the fan rotation selector switch, turn the
starting switch to the ON position but do not start the
engine.
q After the engine is started, even if the fan rotation selector
switch is operated, the fan operation confirmation lamp will
flash to inform the operator that the switching operation
cannot be carried out.
AUTO SHIFT DOWN SWITCH
When this switch (7) is operated to the right, if the load cond itions during travel cause the travel speed to drop, the speed
range is automatically shifted down one range.
Position (a): Auto shift down canceled
Position (b): Transmission is automatically shifted down
For details, see “AUTO SHIFT DOWN FUNCTION (3-101)“.
3-20
OPERATION EXPLANATION OF COMPONENTS
LAMPS 3
F (1) Warning lamp F (3) Fan operation confirmation lamp
F (2) Filter/oil change interval lamp
WARNING LAMP
NOTICE
If alarm buzzer sounds, stop work immediately and perform inspection and maintenance of the appropriate point.
When the caution lamp for the B CAUTION or C CAUTION
groups flashes and an abnormality is detected by the electronic
control system, the alarm buzzer sounds and this lamp (1)
flashes at the same time.
If the lamp flashes, use the monitor panel to check for the location of the abnormality.
3-21
EXPLANATION OF COMPONENTS OPERATION
FILTER/OIL CHANGE INTERVAL LAMP
This lamp (2) lights up when the time for replacing the filter or
oil is near.
FAN OPERATION CONFIRMATION LAMP
After the engine is started, even if the fan rotation selector
switch is operated, this lamp will flash to inform the operator
that the switching operation cannot be carried out.
q Before the engine is started, if the starting switch is turned
ON, and the fan rotation selector switch is set to the
reverse mode (REV) position or clean mode (CLN) POSITION, lamp (3) will light up to inform the operator that the
mode has been set to reverse mode (REV) or clean mode
(CLN). After the engine starts, the lamp goes out.
3-22
OPERATION EXPLANATION OF COMPONENTS
METHOD OF USING DISPLAY PANEL B (Multi-information) 3
EXPLANATION OF MODES AND CONTROLS
q Display panel B (1) has the function of displaying the fol-
lowing four types of mode. (The diagram on the right
shows the normal screen before the mode display.)
Maintenance mode
This displays the time for replacing the filters or oil.
PM clinic auxiliary mode
This displays the engine speed and the oil pressure in the
hydraulic circuits.
Fault display mode
This displays the fault code related to the electronic control.
Adjustment mode
This adjusts the brightness and contrast of the display.
q There are variations (sub-items) in the four types of mode. For an explanation of the va riations, see the follow-
ing items.
METHOD OF USING MAINTENANCE MODE (3-25)
METHOD OF USING PM CLINIC AUXILIARY MODE (3-27)
METHOD OF USING FAULT CODE DISPLAY MODE (3-28)
METHOD OF USING USER ADJUST MODE (3-29)
q The operation of each mode is carried out with information
switch (2) and buzzer cancel switch (3) on the dashboard
in front of the operator's seat.
After operating the switch, if the switch is released, it will
automatically return to the center position as shown in the
diagram on the right.
The functions for each position of the switches are as follows.
<: Mode item display goes back to previous item, cursor
moves to left
>: Mode item display advances to next item, cursor moves
to right
: Selects mode
: Cancels mode
q The four types of mode can be selected in a cycle by operating information switch (2) to > and < to give the fol-
lowing sequence: Maintenance mode ←→ PM clinic auxiliary mode ←→ Fault code display mode ←→ Adjustment mode ←→ Maintenance mode.
q From the normal mode before giving the mode display, if buzzer cancel switch (3) is operated to and held
for 2.5 seconds, the maintenance mod e is displayed. After that, if informat ion switch (2) is ope rated to >, the
mode changes to the PM clinic auxiliary mode. If information switch (2) is operated to <, the mode changes to
the user adjust mode.
q When any mode is being displayed, if the buzzer cancel switch is operated to , the screen returns the normal
screen shown before the mode display.
3-23
EXPLANATION OF COMPONENTS OPERATION
METHOD OF SELECTING MODES
1. When moving from the normal operation display to a user
mode, the maintenance mode is displayed. Use the controls to change the mode as follows.
> position: Go to PM clinic auxiliary mode
< position: Go to user adjust mode
position: Go to normal operation screen
position: Go to maintenance mode selection screen.
2. The diagram on the right shows the screen display for the
PM clinic auxiliary mode. Use the controls to change the
mode as follows.
> position: Go to fault code display mode
< position: Go to maintenance mode
position: Go to normal operation screen
position: Go to PM clinic auxiliary mode selection item
screen
3. The diagram on the right shows the screen display for the
fault code display mode. Use the controls to change the
mode as follows.
> position: Go to adjustment mode
< position: Go to PM clinic auxiliary mode
position: Go to normal operation screen
position: Go to fault code selection item screen
4. The diagram on the right shows the screen display for the
user adjust mode. Use the controls to change the mode as
follows.
> position: Go to maintenance mode
< position: Go to fault code display mode
position: Go to normal operation screen
position: Go to user adjust mode selection item screen
3-24
OPERATION EXPLANATION OF COMPONENTS
METHOD OF USING MAINTENANCE MODE
NOTICE
This function is only a guideline. If dirty oil or filters are found during daily maintenance, replace them
immediately.
If the controllers or monitor panel are replaced, the timer for this function will not work properly. Contact
your Komatsu distributor for replacement.
The maintenance mode shows the replacement interv al for the
oil filters and oil on the monitor.
The content of the display is as follows.
(1) The item is displayed.
(2) The time remaining until replacement is displayed.
(3) The number of times that replacement has been made until
now is displayed.
The display items can be displayed in order by operating the
information switch to the left or right (<, >).
Display Item 1st replacement interval
1. ENG.OIL Engine oil 500h 500h
2. ENG.FILT Engine oil filter 500h 500h
3. FUEL.FILT Fuel filter 500h 500h
4. HYD.FILT Hydraulic oil filter 250h 2000h
5. CORR.RES Corrosion resistor (*) 0h 0h
6. BYPS.FILT Bypass filter (*) 0h 0h
7. DAMP.OIL Damper oil 2000h 2000h
8. FNL.OIL Final drive oil 250h 1000h
9. HYD.OIL Hydraulic oil 250h 2000h
10. POWL.OIL Power train oil 250h 1000h
11. POWL.FILT Power train oil filter 250h 500h
12. HSS.FILT HSS charge filter 250h 1000h
The item marked * is displayed in the above table, but is not used on this machine.
When the oil or filter has been replaced, select the applicable
item, then operate the buzzer cancel switch to .
The screen will ask if you want to display the replacement history.
Operate the information switch to select YES, then operate the
buzzer cancel switch to . The replacement account will
increase by 1, the replacement interval will be reset, and the
oil, filter change interval lamp will go out.
When this is done, if the maintenance caution lamp does not
go out, there is another item close to the replacement time, so
check the situation.
2nd and following replace-
ment intervals
3-25
EXPLANATION OF COMPONENTS OPERATION
REMARK
To return to the function selection mode, operate the buzzer
cancel switch to .
3-26
OPERATION EXPLANATION OF COMPONENTS
METHOD OF USING PM CLINIC AUXILIARY MODE
CAUTION
When moving the work equipment or setting the transmission to the travel position for carrying out measurements, check carefully that the situation is safe.
The PM clinic auxiliary mode displays the engine speed, hydraulic oil pressure, and other items on display panel
B.
Display panel B displays the item on the top line (1), and the
measured value on the bottom line (2).
The display items consist of the six items in the table below.
The items can be selected by operating the information switch (<, >).
Display Item Measured value
01-ENG.SPEED Engine speed Speed (rpm)
02-BOOST PRSSURE Boost pressure Pressure (kPa)
03-HYD.PUMP PRES Hydraulic oil pressure Pressure (MPa)
04-BATTERY VOLT Battery voltage Voltage (mV)
05-HSS PUMP-A HSS A circuit pressure Pressure (MPa)
06-HSS PUMP-B HSS B circuit pressure Pressure (MPa)
REMARK
Sometimes when measuring with the engine running, the display may flicker and be difficult to read. In such
cases, switch the buzzer cancel switch to . The value at that moment is shown on the fixed display.
To cancel this mode, operate the buzzer cancel switch once more to .
To return to each function select ion mode , op er a te th e bu zze r canc el switch to .
The displayed pressure is the absolute pressure.
3-27
EXPLANATION OF COMPONENTS OPERATION
METHOD OF USING FAULT CODE DISPLAY MODE
NOTICE
The fault items observed by this function are connected with the electron ic contr ol, so ev en if a fault code
is not displayed, there is probably some problem with the machine. If the operator feels any problem with
the machine, the machine should be stopped immediately and checked.
When any disconnection or short circuit in any sensor is detected, the location and fault code are displayed by a 6digit code on display panel B. When contacting your Komatsu distributor, info rm your distributor of the code at the
same time.
If the failure observation function has not determined the condition of the machine, the display is as shown in the diagram on
the right.
With this function, existing failures can be displayed up to a
maximum of 20 items.
If multiple failures are occurring, the display automatically
changes every 2 seconds, so check the code.
The display is shown repeatedly.
REMARK
To return to the function selection mode, operate the buzzer cancel switch to .
3-28
OPERATION EXPLANATION OF COMPONENTS
METHOD OF USING USER ADJUST MODE
With the user adjust mode, the brightness of the panel screen backlighting and the contrast of the liquid crystal
panel can be changed, or the cooling fan can be set to maximum speed to clean the radiator when it is clogged.
These are displayed on display panel B.
1. Adjusting backlighting of liquid crystal display
The diagram on the right is the mode for adjusting the
brightness of the backlighting of the liquid crystal panel.
On this screen, operate the buzzer cancel switch to to
switch to the screen to adjust the brightness.
The brightness can be adjusted by operating the information
switch.
The higher the number, the brighter the screen becomes; the
lower the number, the darker the screen becomes.
> position: Number increases
< position: Number decreases
When the buzzer cancel switch is operated to , the brightness of the liquid crystal display backlighting is set.
2. Adjusting backlighting of message display
The diagram on the right is the mode for adjusting the
brightness of the backlighting of the message display. On
the screen, operate the buzzer cancel switch to to
switch to the screen for adjusting the brightness.
3-29
EXPLANATION OF COMPONENTS OPERATION
The brightness can be adjusted by operating the information
switch.
The higher the number, the brighter the screen becomes; the
lower the number, the darker the screen becomes.
> position: Number increases
< position: Number decreases
When the buzzer cancel switch is operated to , the brightness of the message display backlighting is set.
3. Adjusting contrast of liquid crystal message display
The diagram on the right is the mode for adjusting the con-
trast of the liquid crystal message display.
On this screen, operate the buzz er cancel switch to to
switch to the screen to adjust the contrast.
The contrast can be adjusted by operating the information
switch.
The higher the number, the darker the screen becomes; the
lower the number, the lighter the screen becomes.
> position: Number increases
< position: Number decreases
When the buzzer cancel switch is operated to , the contrast
of the liquid crystal display is set.
3-30
OPERATION EXPLANATION OF COMPONENTS
REMARK
To return to the function selection mode, operate the buzzer cancel switch to .
The brightness of the backlighting of the monitor panel differs according to wheth er the front lamp is lit or not.
Entering this mode when the front lamps are lit makes it possible to adjust the brightness wh en the front lamp s are
lit. In the same way, entering this mode when the front lamps are not lit makes it possible to adjust the brightness
when the front lamps are not lit.
3-31
EXPLANATION OF COMPONENTS OPERATION
SWITCHES 3
(1) Horn switch (4) Cigarette lighter (24V)
(2) Room lamp switch (5) Accessory socket (12V)
(3) Wiper switch
HORN SWITCH
The horn sounds when button (1) at rear of the blade control
lever on the right side of operator's seat is pressed.
ROOM LAMP SWITCH
This (2) lights up the room lamp.
ON position: Lamp lights up
OFF position: Lamp is out
3-32
OPERATION EXPLANATION OF COMPONENTS
WIPER SWITCH
Switch (3) activates the wipers.
The wiper switches are as follows:
(LH) Left door
(FF) Front window
(RH) Right door
(RR) Rear window
(INT) Wiper intermittent operation switch
This is also used as the window washer switch.
The switch is operated as follows:
q Window washer only
Keep the switch pressed to the OFF position to spray out
water.
q Wiper only
If this is switched on, the wiper will start.
q Wiper and window washer
If this is kept pressed to the ON position while the wiper is
working, water will be sprayed out.
ON
OFF
ON
OFF
ON
OFF
3-33
EXPLANATION OF COMPONENTS OPERATION
q If the intermittent switch is turned ON, all movement of the
wipers will be intermittent.
ON
OFF
3-34
OPERATION EXPLANATION OF COMPONENTS
REMARK
When installing the cab, check the colors and install the washer
tank and each window washer hose correctly according to the
color.
When installing the cab, carry out the operation in accordance
with the cab installation procedure manual held by your
Komatsu distributor.
1. For right door (red)
2. For front window (colorless)
3. For rear window (black)
4. For left door (blue)
1. Red - Right door
2. Blue - Left door
3. Black - Rear window
4. Colorless - Front window
5. Washer tube
6. From fuse box (red)
(back up power source)
Front of
machine
View Y
1
3
View X
2
4
1
2
3
4
5
6
1. Washer tank
1
View Z
View W
3-35
EXPLANATION OF COMPONENTS OPERATION
CIGARETTE LIGHTER
Lighter (4) is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its original position after a few seconds, so take it out to light your cigarette.
Cigarette lighter capacity: 120W
NOTICE
This cigarette lighter is 24V. Do not use it as the power
source for 12V equipment.
ACCESSORY SOCKET
Socket (5) is used as the power source for a wireless device or
other 12V equipment.
Accessory socket capacity: 60W (12V x 5A)
3-36
OPERATION EXPLANATION OF COMPONENTS
CONTROL LEVERS, PEDALS 3
(1) Fuel control dial (6) Work equipment lock lever
(2) Joystick (steering, directional and gear shift
lever)
(3) Brake pedal
(4) Deceleration pedal
(5) Parking lever
FUEL CONTROL DIAL
Dial (1) is used to control the engine speed and output.
(a) Low idling position: Turn fully to the left
(b) High idling position: Turn fully to the right
REMARK
When stopping the engine, turn the starting switch to the OFF
position.
(7) Blade control lever
(8) Ripper control lever (Variable ripper)
(9) Pin puller control switch (giant ripper)(if
equipped)
MAX
MIN
3-37
EXPLANATION OF COMPONENTS OPERATION
JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER)
(PCCS lever)
This lever (2) is used to switch between forward and reverse, to
steer the machine, or carry out counterrotation turns.
REMARK
PCCS: Palm command control system
q
Forward-reverse shifting
Position (a): FORWARD
Position (b): REVERSE
Position N: Neutral
Move to the front to drive forward; move to t he rear to drive in
reverse.
q
Steering
Position (L): Left turn
Position (R): Right turn
With the lever moved to the front or rear, operate the lever partially to the left or right to turn the machine. The
machine will turn gradually in the same direction as the lever is operated.
If the lever is moved fully to the left or right, the machine will turn in a small radius.
REMARK
If the lever is released when steering the machine, the lever will return to the (a) position or the (b) position and the
machine will be returned to straight movement.
q
Gear shifting
When the joystick (steering, direction, and gearshift lever) is in
the FORWARD or REVERSE position, press switch (c) or (d) to
shift the transmission.
up switch (c): Each time the switch is pressed, the transmission
shifts up one speed range.
down switch (d): Each time the switch is pressed, the transmission shifts down one speed range.
For details of the maximum travel speed in each speed range,
see “SPECIFICATIONS (5-2)“.
REMARK
When the transmission is shifted, the speed range being use d is displayed on the display panel on the monitor
panel.
Example:
Neutral: N is displayed on the display panel.
FORWARD 2nd: F2 is displayed on the display panel.
REVERSE 3rd: R3 is displayed on the display panel.
When the parking lever is locked, P is displayed.
For details of the gearshift operation using the shift mode, see “SHIFTING GEAR (3-99)“. Shift mode selection
means the operation to set the selected speed range beforehand in the N position.
3-38
OPERATION EXPLANATION OF COMPONENTS
q Operating counter-rotation turn
WARNING
When operating the counter-rotation turn, if the load on
the left and right is not balanced, the machine may make a
pivot turn, so check the ground co nditions and be careful
not to hit any obstacles when carrying out the operation.
With the lever in the N position, move the lever partially in the
direction of turn. The left and right tracks will rotate in opposite
directions, and the machine will make a slow co unter-rotation
turn. If the lever is moved further, the speed of the counterrotation turn will increase.
(R): Right counter-rotation turn
(L): Left counter-rotation turn
3-39
EXPLANATION OF COMPONENTS OPERATION
BRAKE PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.
Depress the pedal (3) to apply the right and left brakes.
DECELERATION PEDAL
WARNING
q Do not place your foot on this pedal unnecessarily.
q When passing over the top of a hill or when a load is
dumped over a cliff, the load is suddenly reduced, so
there is danger that the travel speed will also increase
suddenly. To prevent this, depress the decelerator
pedal to reduce the travel speed.
Pedal (4) is used when reducing engine speed or stopping the
machine.
When switching between forward and reverse, or when stopping the machine, use this pedal to reduce speed.
PARKING LEVER
WARNING
When the machine is parked, always set the parking lever
to the LOCK position.
Lever (5) is used to apply the parking brake.
REMARK
Before moving the parking brake lever to the LOCK position,
return the steering, directional, and gearshift lever to the N
position.
When starting the engine, if the parking brake lever is not in the
LOCK position, the limit switch is actuated and it is impossible
to start the engine.
Free
Lock
3-40
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