CEAM002501

BULLDOZER
D51EX - 22

D51EX-22 ･D51PX-22
D51PX - 22
SERIAL NUMBERS B10001 and up

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 near the machine for
reference and periodically reviewed by all personnel
who will come into contact with it .

NOTICE
Komatsu has Operation & Maintenance Manuals written
1 in some other languages. if a foreign language manual
is necessary, contact your local distributor for
©2008 KOMATSU availability.
All Right Reserved
Printed in Brazil 09-08
 CEAM002501

Operation & Maintenance

Manual

D51EX-22
D51PX-22 BULLDOZER

D51EX-22 B10001
SERIAL NUMBERS and UP
D51PX-22 B10001
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

September 2008 Copyright 2008 Komatsu

Published in USA
Komatsu America Corp.
 0INTRODUCTION

D51EX/PX-22 0-1
INTRODUCTION
FOREWORD
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 accidents are caused by the failure to
follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing
beforehand conditions that may cause a hazard when performing operation and maintenance.

Before beginning operation or maintenance, operators and maintenance personnel must always observe
the following points.

Read this manual thoroughly and understand its contents fully.

Read the safety messages and safety labels given in this manual carefully so that they should be
understood fully.

Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all
personnel involved in working on the machine can consult it periodically.

In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor
to obtain a new copy.

When you sell the machine, make sure that this manual should be provided to the new owner together with
the machine.

In this manual, measurements are expressed in international standard units (SI). For the reference
purpose, weight units used in the past are also displayed in ( ).

Storage location for the Operation and Maintenance Manual:

Pocket in the back of the operator's seat (fitted with a lock).

Remark
For air suspension seat installations the storage for the
operators manual is in a sheet metal pocket behind the
operators seat.

0-2 D51EX/PX-22
 INTRODUCTION
SAFETY INFORMATION
Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the machine.
To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before
performing maintenance and machine operations.

To identify safety messages in this manual and on machine product graphics, the following signal words are used:

DANGER! - This word is used on safety messages and product graphics where there is a high probability of serious injury or
death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that
must be taken to avoid the hazard. Failure to avoid this hazard may result in serious damage to the machine,
injury or even death.

WARNING! - This word is used on safety messages and product graphics where there is a potentially dangerous situation,
which could result in serious injury or possibly death if the hazard is not avoided. These safety messages and
product graphics usually describe precautions that must be taken to avoid the hazard. Failure to avoid this
hazard may result in serious damage to the machine or possible injury.

CAUTION! - This word is used on safety messages and product graphics for hazards, which could result in minor or moderate
injury if the hazard is not avoided. These safety messages and product graphics might also use this word for
hazards where the only result could be damage to the machine.

Remark
This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage
the machine.

Safety precautions are described in SAFETY section 1.

KOMATSU cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore
the safety message 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, you must be sure that you and others can do such
procedures and actions safely and without damaging the machine or causing injury. If you are unsure about the safety of some
procedures, contact your local KOMATSU Distributor.

D51EX/PX-22 0-3
INTRODUCTION
APPROVED AND NON-APPROVED USES
The Komatsu BULDOZER described in this manual has been designed and constructed to be used mainly for the following
functions, any non-approved used may void the warranty, damage the machine or possibly injure the operator.

APPROVED
• DOZING.
• SCRAPING OR GRADING OPERATIONS.
• EXCAVATING.
Installation of optional equipment can also be used in the following applications, use only KOMATSU approved equipment.

NON-APPROVED
This paragraph describes some of the improper or unauthorized uses of the machine; since it is impossible to predict all the
possible improper uses, if the machine happens to be used for any particular application other than those approved above, it is
important to contact your Authorized Komatsu Dealer before carrying out the work operations.

• USE OF MACHINE FOR LIFTING OR TRANSPORTING PERSONNEL IN ANY MANNER.

• USE OF MACHINE IN COAL OR FLAMABLE MATERIAL MOVEMENT.
• TRANSPORTATION OF FLAMMABLE LIQUIDS.
• MOVING OR TRANSPORTING OTHER MACHINES WITH THE FRONT DOZER BLADE.
• TOWING NON-APPROVED ATTACHMENTS WITH THE DRAWBAR.
• TOWING THE MACHINE AT HIGH SPEEDS.
• TRAVELING AT HIGH SPEEDS.

0-4 D51EX/PX-22
 INTRODUCTION
PRODUCT IDENTIFICATION
The serial numbers and model numbers on the components are the only numbers that your dealer will need when requiring
assistance or ordering replacement parts. It is a good idea to record this information in this manual on page 0-9 (Serial Number
And Dealer Information). All views indicated below are viewed from the operator’s position.

PRODUCT IDENTIFICATION PLATE

The identification plate is located inside the operators cab.

D51EX/PX-22 0-5
INTRODUCTION
ENGINE SERIAL NUMBER AND EMISSION LABEL

• Top of valve cover

• Front part of engine

0-6 D51EX/PX-22
 INTRODUCTION
SERIAL NUMBERS AND DEALER INFORMATION

MODEL: D51EX/PX-22

Machine #

Engine #

Dealer:

Address:

Phone #
Contacts:

NOTES:

D51EX/PX-22 0-7
INTRODUCTION
CONTENTS
INTRODUCTION

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
APPROVED AND NON-APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
NON-APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
PRODUCT IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
ENGINE SERIAL NUMBER AND EMISSION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
SERIAL NUMBERS AND DEALER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
MODEL: D51EX/PX-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8

SAFETY

SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
GENERAL SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
GENERAL SAFETY AT JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
WORKING ON LOOSE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
FIRE CAUSED BY FUEL OR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL . . . . . . . . . . . . . 1-11
FIRE FROM ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
FIRE FROM HYDRAULIC LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
WINDSHIELD WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
ACTION IF FIRE OCCURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
DUST HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
KEEP OPERATOR'S CAB CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
LEAVING OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
PARKING BRAKE AND EQUIPMENT LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
CRUSH OR PINCH POINT DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
INSIDE OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
PRECAUTIONS WHEN USING ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
PRECAUTIONS BEFORE STARTING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
WORK SITE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
AVOIDING DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
HIGH VOLTAGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
0-8 D51EX/PX-22
 INTRODUCTION
RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
PRECAUTIONS WHEN TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
USING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
RULES FOR TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
TRAVELING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
WORKING ON LOOSE OR UNSTABLE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
TRAVEL ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
PRECAUTIONS DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
USING DROP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
RUNNING THE MACHINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
RULES FOR REFUELING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
WORK UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
PRECAUTIONS WHEN USING HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Turn the battery disconnect switch to the OFF position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
REPAIR WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
ENGINE SYSTEM HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
BATTERY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
HANDLING HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
PRECAUTION FOR HIGH FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
HIGH TEMPERATURE AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
ROTATING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION . . . . . . . . . . . . . . . . . . 1-31
DO NOT DISASSEMBLE RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
LOADING AND SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

OPERATION

GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
VIEW OF CONTROLS AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
MONITOR BEZEL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
BASIC OPERATION OF MONITOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
CHECK MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
MONITOR CHECK ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
EMERGENCY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

D51EX/PX-22 0-9
INTRODUCTION
ENGINE OIL PRESSURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ENGINE COOLANT TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
HYDRAULIC OIL TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
HST CHARGE PRESSURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
CHARGE FILTER CLOG CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
WARNING ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
BATTERY CHARGE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
AIR CLEANER CLOGGING CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
WATER IN FUEL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
MAINTENANCE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
CONSOLE CONTROL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
SWITCH LAYOUT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
BUZZER CANCEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
INFORMATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
HEATER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
CAB LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
ACCESSORY SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
HYDRAULIC OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
DISPLAY PANEL (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
FUEL LEVEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
REVERSE TRAVEL SPEED SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
SHIFT MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
ENGINE INTAKE AIR PRE-HEAT PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
DISPLAY PANEL (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
FAN ROTATION SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
WARNING LAMP VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
WARNING LAMP (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
USING FAILURE CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
USING MAINTENANCE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
METHOD OF SELECTING EACH MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
USING OIL AND FILTER MAINTENANCE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
USING ADJUMENT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
CONTROL LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
LEVER LAYOUT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
LOCK LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
TRAVEL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
BLADE ANGLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
WORK EQUIPMENT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
DECELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
0-10 D51EX/PX-22
 INTRODUCTION
PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
DOOR AND WINDOW SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
DOOR - OPEN LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
SASH GLASS INTERMEDIATE LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
SAFETY LOCKS AND SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
CAP, COVER WITH LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
OPENING AND CLOSING CAP WITH LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
LOCKABLE AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
SEAT POCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
ADDITIONAL FEATURES AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
AIR CONDITIONER AND FEET HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
GENERAL DESCRIPTION OF CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
BLOWER SPEED SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
TEMPERATURE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
PRECAUTIONS WHEN USING AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
FEET HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
EXPLANATION OF FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
POWER SWITCH/VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
AUTO-STORE/PRESET SCAN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
BASS CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
TREBLE CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
LOUDNESS BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
TIME/RADIO DISPLAY SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
TAPE EJECT BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
CASSETTE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
FAST FORWARD, REWIND BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
PRESET BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
METAL TAPE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
MANUAL TUNING BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
SEEK TUNING BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
BAND SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
LISTENING TO RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
LISTENING TO A CASSETTE TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
REVERSING TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
PRECAUTION WHEN USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
ASHTRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
LUNCH BOX HOLDER STRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
CUP HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
TOOL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
GREASE PUMP HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
ELECTRICAL POWER ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
FUSE CAPACITIES AND CIRCUIT NAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
D51EX/PX-22 0-11
INTRODUCTION
PRECAUTIONS BEFORE STARTING WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
WALK-AROUND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
AIR SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
ADJUST ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
FASTENING AND REMOVING SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
ADJUSTING MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
SYSTEM “ON” CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
NORMAL OR COLD START PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
COLD WEATHER STARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
OPERATIONS AND CHECKS AFTER STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
BREAKING IN THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
WARMING UP ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
STARTING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
MOVING, STEERING, STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . 2-88
PREPARATIONS FOR MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
MOVING MACHINE FORWARD OR REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
CHANGING SPEED RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
STEERING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
NORMAL TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
MAKING A LEFT OR RIGHT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
MAKING A PIVOT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
TURNING WHILE DESCENDING A SLOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
COUNTER-ROTATION TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
STOPPING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
PARKING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
CHECK AFTER FINISHING WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
CHECK AFTER SHUTING OFF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
AVOIDING DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
HIGH VOLTAGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
PAY ATTENTION TO GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
PERMISSIBLE WATER DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
METHOD OF USING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
WHEN TRAVELING UP OR DOWN HILLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
PRECAUTIONS ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
1. BE AWARE OF FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
2. PRECAUTIONS WHEN ENGINE STOPS ON A SLOPES . . . . . . . . . . . . . . . . . . . . . . 2-103
ALWAYS KEEP THE DOORS CLOSED DURING OPERATIONS . . . . . . . . . . . . . . . . . 2-103
DO NOT MODIFY THE CAB GLASS IN ANY WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAYS . . . . . . . . . . . . . . . . . 2-103
CUTTING A GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
DOZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
BACK GRADING A SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
CUTTING HARD OR FROZEN GROUND OR DITCHING . . . . . . . . . . . . . . . . . . . . . . . 2-105
0-12 D51EX/PX-22
 INTRODUCTION
FELLING TREES, REMOVING STUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
SIDE-CUTTING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
UNDERCARRIAGE CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
OPERATION METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
MEASURING LINK PITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
MEASURING HEIGHT OF GROUSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
MEASURING OUTSIDE DIAMETER OF TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . 2-108
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
LOADING OR UNLOADING A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
PRE-TRANSPORTATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
SECURING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
COOLING SYSTEM COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115
PRECAUTIONS ON PARTICULAR JOBSITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
DISCHARGED BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
REMOVE AND INSTALL BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117
BATTERY CHARGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117
STARTING ENGINE WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118
GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
AFTER RUNNING OUT OF FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
WHEN IT IS POSSIBLE TO START ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
WHEN ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
RELEASING THE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
CONNECTING PUMP TO MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
AFTER TOWING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124
ELECTRICAL SYSTEM PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125
MONITOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-126
CHASSIS PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127
ENGINE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128
LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
BEFORE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
AFTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
MACHINES EQUIPPED WITH KOMTRAX SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131

MAINTENANCE

MAINTENANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

SERVICE METER READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
KOMATSU GENUINE REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
KOMATSU GENUINE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

D51EX/PX-22 0-13
INTRODUCTION
WINDSHIELD WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
FRESH AND CLEAN LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
CHECK DRAINED OIL AND USED FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
WELDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
DO NOT DROP THINGS INSIDE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
DUSTY JOBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AVOID MIXING LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
HYDRAULIC SYSTEM - AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
HYDRAULIC HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS . . . . . . . . . . . . . . . . . . . . . . 3-3
LOCKING THE INSPECTION COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
OPENING OR CLOSING RADIATOR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
LUBRICANTS, COOLANT AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
OUTLINE OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC . . . . . . . . . . . . . . . . 3-6
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
COOLING SYSTEM COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS) . . . . . . . . . . . . . . . . . . . . 3-7
OIL AND FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ELECTRIC SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
HANDLING HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
WEAR PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS . . . . . . . . . . . 3-13
LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 3-14
TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
SAFETY RELATED CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
MAINTENANCE WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CLEAN TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CLEANING THROUGH ACCESS AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CHECK ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ENGINE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
CLEANING OR REPLACING OUTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
REPLACING INNER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
CLEAN COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
FLUSHING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
TRACK SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
CHECK AND TIGHTEN TRACK SHOE BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
0-14 D51EX/PX-22
 INTRODUCTION
CHECKING AND ADJUSTING TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
IDLER GUIDE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
REVERSING OR REPLACING END BITS AND CUTTING EDGES . . . . . . . . . . . . . . . . . . . 3-35
ADJUST PLAY IN CENTER BALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
DOOR HINGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
CHECKING WINDOW WASHER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
MIXTURE RATIO OF PURE WASHER FLUID AND WATER . . . . . . . . . . . . . . . . . . . . . 3-38
CHECKING AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
CHECK LEVEL OF REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
OPERATING AIR CONDITIONER OFF-SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
REPLACE WIPER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
RELEASING INTERNAL PRESSURE ON HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 3-41
BLEEDING AIR FROM HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
BLEEDING AIR FROM PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
BLEEDING AIR FROM CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
CLEAN, CHECK RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
CLEANING BY ROTATING COOLING FAN IN REVERSE DIRECTION . . . . . . . . . . . 3-43
CLEANING WITH COMPRESSED AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
EVERY 50 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
DRAINING SEDIMENT FROM FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
EVERY 250 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHECK OIL LEVEL IN FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHECKING FINAL DRIVE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
LUBRICATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHECK LEVEL OF BATTERY ELECTROLYTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
CHECK BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) . . . . . . . . . . . . . . . . . . . . . . . . 3-54
EVERY 500 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
REPLACE FUEL PRE-FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTER CARTRIDGE . . . 3-58
EVERY 1000 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
CHANGE OIL IN FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
CHECK ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS . . . . . . . . . . . 3-60
CHECK FOR LOOSE ROPS MOUNT BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
REPLACE PRE AND MAIN FUEL FILTER CARTRIDGES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
EVERY 2000 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE . . . . . . . . . . 3-64
CHECK ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
CHECK ENGINE VALVE CLEARANCE, ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
REPLACE HYDRAULIC TANK BREATHER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
CHECKING CHARGE PRESSURE ACCUMULATOR (CONTROL CIRCUIT) . . . . . . . . . . . 3-68
FUNCTION OF ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
CHECKING FUNCTION OF ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
RELEASING PRESSURE IN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
D51EX/PX-22 0-15
INTRODUCTION
CHECKING PIVOT SHAFT OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
CHECKING IDLER OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
EVERY 4000 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
CHECK WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
CHECK VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
CHECK STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
CHECKING FOR MISSING FUEL SPRAY CAP, HARDENING OF RUBBER . . . . . . . . . . . 3-71

SPECIFICATIONS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
OPERATING WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
MACHINE DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
MACHINE SYSTEMS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
SERVICE REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

OPTIONAL ATTACHMENTS

AUTHORIZED OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
DELUXE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
FORESTRY KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
CABIN POLYCARBONATE PANEL FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

0-16 D51EX/PX-22
 1SAFETY
WARNING!
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety section also contains precautions for optional
equipment and attachments.

D51EX/PX-22 1-1
SAFETY
SAFETY AND WARNING DECALS
It is important that all safety and warning decals are in place, not damaged, covered up or removed. It is also important for the
operator to be aware of the decal content and location.

1-2 D51EX/PX-22
 SAFETY

LOCATION OF THE SAFETY DECALS

• Your Komatsu Dealer can supply you with new replacement decals if the ones on the machine are damaged or missing.
• When replacing damaged or missing decals, be sure they are placed in the proper location.
• Additional safety or warning decals may be added to your machine if desired

1. Warning before operating or maintaining machine

(09651-A0481).

Improper operation and maintenance can cause serious injury or

death.

Read manual and labels before operation and maintenance.

Follow instructions and warnings in manual and in labels on
machine.

Keep manual in machine cab near operator.

Contact Komatsu distributor for a replacement manual.

2. Warning before moving in reverse (09802-13000)

To prevent SEVERE INJURY or DEATH, do the following before moving

machine or its attachments.

• Honk the horn to alert people nearby.

• Be sure no one is on or near machine.
• Use spotter if view is obstructed.

Follow above even if machine is equipped with back-up alarm and mirrors.

D51EX/PX-22 1-3
SAFETY
3. Warning for leaving operators seat (09654-B0481).

To avoid hitting unlocked operation levers, before standing up from

operator’s seat, do the following.

• Move steering and directional lever neutral and move LOCK

LEVER (located left of seat) to LOCK position.
• Lower equipment to ground and move LOCK LEVER (located
right of seat) to LOCK position.

Sudden and unwanted machine movement can cause serious injury or

death.

4. Warning for high-temperature coolant (09653-A0481).

Hot water hazard

To prevent hot water from spurting out:

• Turn engine off.
• Allow water to cool.
• Slowly loosen cap to relieve pressure before removing.

5. Warning for high temperature oil (09653-A0481)

Hot oil hazard

To prevent hot oil from spurting out:

• Turn engine off.
• Allow oil to cool.
• Slowly loosen cap to relieve pressure before removing.

1-4 D51EX/PX-22
 SAFETY
6. Warning for adjusting track tension (09657-A0881) (two places).

Compressed spring and lubricator are under hazardous high pressure and can
cause serious injury or death.

• When adjusting track tension, only turn lubricator ONE TURN, turning
lubricator further could cause lubricator and grease to fly out and hurt
you.
See manual for adjustment instructions.
• When loosening track shoe, if it does not loosen after turning lubricator
ONE TURN, ask a Komatsu dealer or distributor to disassemble.

7. Warning for battery cables (09808-A0881)

Improper use of booster cables and battery cables can cause an

explosion resulting in serious injury or death.

• Follow instructions in manual when using booster cables and

battery cables.

8. Warning when handling battery (09664-60000).

EXPLOSIVE GASSES.
Cigarettes, flames or sparks could cause battery to explode. Always
shield eyes and face from battery, DO not change or use booster
cables or adjust post connections without proper instructions or
training.
KEEP VENT CAPS TIGHT AND LEVEL.

POISON causes severe burns.

Contains sulfuric acid. Avoid contact with skin eyes or clothing. In
event of accident flush with water and call a physician immediately.
KEEP OUT OF REACH OF CHILDREN.

9. Warning for engine running (09667- A0481) (two places).

While engine is running:

1. Do not open cover.

2. Keep away from fan and fan-belt.

D51EX/PX-22 1-5
SAFETY
10. Warning when approaching machine when it is being operated
(09805-B0883) (two places).

11. Warning for ROPS (09620-A2000).

12. Prohibited to jump start machine in this manner

(09842-A0481).

Start the machine only when sitting in the operator’s seat.

Do not attempt to start the engine by short circulating the starter.

13. Warning with high-temperature parts (09817-A0753).

This sign indicates high temperature parts.

14. Warning with handling accumulator parts (09659-A057B).

This sign indicates explosion hazard.

• Keep away from flame.
• Do not weld or drill.

1-6 D51EX/PX-22
 SAFETY
Ground noise level decal (09696-40109).

Cabin noise level decal (09696-50080).

D51EX/PX-22 1-7
SAFETY
GENERAL SAFETY RULES AND PRECAUTIONS

GENERAL SAFETY RULES

Only trained and authorized personnel shall be allowed to operate and service this machine.

Before operating this machine it is important to study the operator’s manual thoroughly and become familiar with all controls
and safety decals. Keep this manual with your machine at all times for easy and quick reference.

Safety must always be the operator’s most important concern. Never operate a machine that is unsafe or in poor operating
condition.

Always perform a pre-operational check on your machine before operating it.

If the machine is equipped with a seat belt and rollover protective structure, OSHA requirements states that the operator
remain within the confines of the rollover protective structure, with the seat belt fastened snugly around their waist before
operating the machine.

OSHA requirements state if your equipment is designed for operation by one person, it is for one person only, never allow
other personnel to ride on your machine.

Never leave your machine running and unattended. Always park the machine in a level area, lower any work equipment to the
ground, set the parking brake, lock the controls and turn the engine off before exiting the operator’s compartment.

Be sure that all personnel are at least 12 m (40 ft) away from any point on the machine before moving or operating the
machine. Never allow anyone to stand near the machine while in operation. Remember, the larger the machine the more
restricted your visibility will be.

If pedestrians are in the area proceed slowly and sound your horn. Keep in mind, pedestrians have the right away, and a loaded
or smaller machine has the right of way over an unloaded machine.

Never use your machine for tasks it was not designed for, damage to the machine or injury to the operator may result.

Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine.

It is the owner and /or operator’s responsibility to replace any safety or warning decals if they are defaced or removed from the
machine.

Think before you act, study the job carefully. Careful operator’s and service personnel are the best insurance against accidents.

The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs or medications that
might affect their eyesight, hearing, or reactions.

When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand
signals that are to be used.

When leaving a job site for long periods of time always lower all work equipment to the ground, neutralize work equipment
controls and lock and secure your machine properly to avoid tampering by other personnel.

Never drive up to anyone standing in your path of travel. Always be sure all personnel are standing to the side when you
approach them and acknowledge your approach.

Follow all rules relating to safety as outlined in this manual and by your company, never get involved in horseplay.

1-8 D51EX/PX-22
 SAFETY

UNAUTHORIZED MODIFICATIONS
If this machine is modified without permission from Komatsu, there is a danger that problems may occur with safety that may
lead to serious personal injury.
Modifications may have an adverse effect on items such as machine strength and visibility.
Before making any modifications, please consult your Komatsu distributor. Komatsu cannot take any responsibility for
accidents, failures, or damage caused by modifications not authorized by Komatsu.

GENERAL SAFETY AT JOB SITE

• Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
• Know your location to report an accident or fire. In case of an emergency, have a local emergency phone number
available.
• Be careful when operating around or near open burning operations.
• Maintain the fire extinguisher on the machine and a second one at the job site
• Keep the machine clean, especially from flammable materials such as trash, grease, oil or fuel.
• Keep all safety equipment in good working condition.
• Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
• Do not operate where there is a hazard of landslides or falling rocks.
• If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility company
and have them identify their locations.
• Take action to prevent unauthorized people from approaching the job site.
• When working on public roads, position flagmen and erect barriers to ensure the safety of passing traffic and pedestrians.
• 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.
• Conduct periodic safety training and familiarize all personnel with emergency procedures.

WORKING ON LOOSE GROUND

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 collapse under the weight or vibration of the machine, there is a hazard that the
machine may fall or tip over.
Remember that the soil is loose after heavy rain, blasting and earthquakes.
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.

D51EX/PX-22 1-9
SAFETY
SAFETY FEATURES
Be sure all guards and covers are in place especially after servicing the machine.

Have guards or covers repaired immediately if they are damaged. See “PRE-OPERATIONAL CHECKS” on page 2-61.

Use safety equipment such as safety locks and seat belt properly.

Never remove any safety features. Always keep them in good operating condition.

Always secure the machine in a safe position: See “MOVING, STEERING, STOPPING AND PARKING THE MACHINE”
on page 2-86.

Seat belt: See “FASTENING AND REMOVING SEAT BELT” on page 2-74.

Improper use of safety features could result in serious bodily injury or death.

Be sure the machine has the correct equipment required by local rules and regulations.

PERSONAL PROTECTIVE EQUIPMENT

If your machine is equipped with safety equipment, OSHA law requires
this equipment to be used when operating your machine.

Avoid loose fitting clothing, jewelry and loose long hair. These can
catch on controls or in moving parts and cause serious injury.

Wear a hard hat, safety glasses, safety shoes, mask or gloves when
operating or maintaining the machine.

Always wear safety goggles, hard hat and heavy gloves, if your job
involves driving pins with a hammer or cleaning the air cleaner
element with compressed air.

Check to be sure no one is near your work area.

Check to be sure all personal protective equipment are in good

condition before using.

If you will be subject to loud noise always wear ear protection.

1-10 D51EX/PX-22
 SAFETY
FIRE AND EXPLOSION PREVENTION
Fuel and oil are flammable. Fuel is particularly flammable and can be
hazardous. Always observe the following:
• Keep any open flames, airborne sparks or burning embers away
from flammable fluids.
• Stop the engine and do not smoke when refueling.
• Tighten all fuel and oil caps securely.
• Refueling or adding oil should be made in well ventilated areas.
• Clean up any fluid spills.

FIRE CAUSED BY FUEL OR OIL

Fuel and oils are particularly flammable and can be hazardous.
To prevent fire, always observe the following:
• Do not smoke or use any flame near fuel or oil.
• Stop the engine before refueling.
• Do not leave the machine while adding fuel or oil.
• Tighten all fuel and oil caps securely.
• Always inspect the entire fuel system for leaks, seepage, or
deteriorated fuel hoses, clean repair or replace if needed.
• Inspect fuel system for leak or seepage, this includes fuel lines,
filters and injection system, clean or repair if required.
• Do not spill fuel on overheated surfaces or on parts of the electrical
system.
• Use well-ventilated areas for adding or storing oil and fuel.
• Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• When carrying out grinding or welding work on the chassis, move any flammable materials to a safe place before starting.
• When washing parts with oil, use a non-flammable oil.
• Diesel oil and gasoline may catch fire, so do not use them.
• Put greasy rags and other flammable materials into a safe container to maintain safety at the work place.
• Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.

FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL

• Remove any dry leaves, wood chips, pieces of paper, wood dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, air cleaner or battery, or inside the undercovers.
• Be aware that operations such as logging, mulching, clearing, and landfill work may cause trash and debris to accumulate
on the machine. Always remove accumulated trash and debris on a daily basis.
• Clean the machine after servicing the hydraulic system, engine or fuel system.
• Operations near burn piles or other open burning may cause airborne sparks or glowing embers to cause a fire on the
machine.

D51EX/PX-22 1-11
SAFETY

FIRE FROM ELECTRICAL SYSTEM

Short circuits in the electrical system can cause fire.
Always keep electric wiring connections clean and securely tightened.
Check the wiring every day for looseness or damage to the wire insulation.
• Tighten any loose connectors or wiring clamps.
• Repair or replace any damaged, pinched or chaffed wiring.
• Aftermarket radios or other electrical operated equipment in the cab must be fused close to the power supply.
• Never use a machine with a higher voltage to jump start your machine.

FIRE 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.
• Check for oil leaks daily and repair them immediately.

WINDSHIELD WASHER FLUID

• Use an automotive type washer fluid in the windshield washer system.
• Never use flammable fluids in the windshield washer system.

ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows:
• Do not attempt to move the machine or continue operations.
• Turn the start switch OFF to stop the engine.
• Use the handrails and steps to get off the machine.
• Immediately call for help.
• When using a fire extinguisher, always aim the extinguisher at the base of the fire.
• If an optional fire extinguishing system is in place be familiar with it’s operating procedures.

DUST HAZARDS

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:
• Spray water to keep down the dust when cleaning. Do not use
compressed air for cleaning.
• 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.
• Do not allow other persons to approach during the operation.
• 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.

1-12 D51EX/PX-22
 SAFETY

KEEP OPERATOR'S CAB CLEAN

• 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 on your shoes, your foot may slip and this may cause an accident.
• Do not leave parts or tools lying around the operator's compartment.
• Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
• Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
• Never bring any dangerous objects such as flammable or explosive items into the operator's cab.

UNAUTHORIZED MODIFICATIONS
Any modification made without authorization from Komatsu can create a hazards. Before making any modifications, consult
your local distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modifications.

D51EX/PX-22 1-13
SAFETY
LEAVING OPERATOR’S COMPARTMENT
Below are listed procedures that must be followed when exiting the operator’s cab.

1. Lower all work equipment to the ground and neutralize the

controls.
2. Turn the ignition key to the “OFF” position and remove ignition
key and keep the key with you.

3. Use the key to lock and secure all the equipment locks. This will
prevent other unauthorized personnel from tampering with your
machine. Keep in mind you are responsible for securing your
machine.

PARKING BRAKE AND EQUIPMENT LOCKS

• Before standing up from the operator's seat (such as when adjusting
the operator's seat), lower the work equipment completely to the
ground, set work equipment lock lever (6) and parking brake lever
(7) 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.

• When leaving the machine, always lower the work equipment

completely to the ground, set work equipment lock lever (6) and
parking brake lever (7) 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.

Remark
Never leave your machine running and unattended, even for
a moment.

Work equipment posture: See “PARKING MACHINE” on page 2-95.

Lock: See “SAFETY LOCKS AND SECURITY” on page 2-42.

1-14 D51EX/PX-22
 SAFETY
MOUNTING AND DISMOUNTING
Use all hand holds and step plates on your machine.

Never jump off or onto the machine.

Before getting on the machine, if there is any oil, grease, or mud on your
shoes, rails, steps or platforms, wipe it off immediately, always keep
these areas clean, and in good condition.

Never get on or off a moving machine. These actions may lead to

serious injury. Always bring the machine to a full stop.

Be sure machine is at a full stop, equipment lowered and parking brake

set before entering or exiting machine.

Never hold any control levers when getting on or off the machine.

When getting on or off the machine, always face the machine and
maintain a Three Point Contact (both feet and one hand or one foot
and both hands) with the handrails, steps and platforms to ensure that
you support yourself properly.

CRUSH OR PINCH POINT DANGERS

The clearance around the work equipment will change according to the
movement of the blade. If you get caught, this may lead to serious
personal injury. Do not allow anyone to approach any part of the
machine while in operation.

FIRE EXTINGUISHER AND FIRST AID KIT

As a precaution if a fire or an injury should occur, always keep a fire
extinguisher and first aid kit on your machine and do as follows:
• Be sure that fire extinguisher is in good condition and read the label
on it to ensure you know how to use it.
• Keep a first aid kit in the storage area. Check the kit periodically
and make any additions if necessary.
• Keep a list of emergency phone numbers in case of an accident.

D51EX/PX-22 1-15
SAFETY
INSIDE OPERATOR’S COMPARTMENT
When entering the operator’s compartment, always remove mud and oil from the
soles of your shoes. If you operate the brake pedal with mud or oil on your shoes,
your foot may slip and may cause an accident.

After using the ashtray, make sure matches or cigarettes are properly extinguished and
be sure to close the lid. If the ashtray is left open, there is danger of fire.

Do not leave lighters or aerosol cans lying around the operator’s compartment. If the
temperature inside the operator’s compartment get’s too high, there is danger that the
lighter may explode.

Do not stick suction pads to the window glass. Suction pads may act as a lens and
could cause fire.

Aftermarket radios or other electrically operated equipment in the cab must be fused close to the power supply.

Keep the operator’s compartment clean, never allow trash or tools to accumulate, these may hinder the operation of the
controls or pedals.

When operating the machine, do not put your hands or head out of the window or beyond the protection of the ROPS.

Always use the seat belt equipped with your machine. Even when using the loader or dozer unit. Be sure the seat belt is
fastened snugly around your waist before operating the machine.

PRECAUTIONS WHEN USING ROPS

The ROPS (Roll Over Protective Structure) must never be removed from the machine. The ROPS is installed to protect the
operator if the machine should roll over. It is designed not only to support the load if the machine should roll over, but also to
absorb the impact of the energy. The ROPS should be replaced if damaged or it must be recertified by a qualified person.

The ROPS fulfills all the regulations and standards for all countries, but if it is modified without authorization or is damaged,
the strength may be reduced and it may not able to fulfill its function properly.

1-16 D51EX/PX-22
 SAFETY
PRECAUTIONS BEFORE STARTING OPERATIONS
As an operator of the machine, you are responsible for the safe operation of the machine at all times regardless of the
situation. Although KOMATSU cannot cover all operating conditions that pose a major hazard, listed below situations to
avoid when using the bulldozer during work or travel operations. It is advised to study these and always be aware of them
before starting your work operations. Failure to do so may result in damage to the machine or injury to the operator and other
personnel.

PRE-OPERATIONAL CHECKS
Before starting your work operations it is important to perform a Pre-operational Check to be sure your equipment is in safe
operating condition. If any problems are found during your pre-operational check, have them repaired immediately. Never
operate a machine that is unsafe, damaged or in need of repair. Failure to perform a pre-operational check before starting work
operations may result in damage to the machine or injury to the operator and other personnel.
Remark
It is important that a pre-operational check be performed at the beginning of your work shift. Even if you are
taking the machine operations over from another operator, always perform a pre-operational check before you
start work. See “PRE-OPERATIONAL CHECKS” on page 2-61.

STARTING YOUR WORK OPERATIONS

• Before operating the machine, walk around it and check for people or objects that might be in the way.
• Do not start the engine if warning tags have been attached to the steering wheel or control levers.
• Sound your horn to warn others in the area before starting the engine or moving the machine.
• Operate the machine in a seated position only, with the seat belt fastened snugly around your waist.
• Do not allow anyone in the cab or on the machine during operations.
• Be sure all personnel are clear from your work site before starting any work operations.

WORK SITE HAZARDS

Before proceeding with any dozing operations it is important to be
aware of the hazards involved with this operation. Below is a list
outlining what to do to avoid some of these hazards.
• Before starting any excavating operations, contact all utility
departments in your area and have them identify and mark any
underground system locations, (gas lines, water lines, electrical
lines, sewer lines, etc.).
• Check your work area for any unusual ground conditions.
• Make sure your work area is as level as possible and you will be
able to maneuver your work equipment or machine easily.
• If you will be working near a high traffic area, (pedestrians or cars)
have a dedicated worker available to direct traffic or install safety fencing around your work site.
• Always be aware of all your work site dangers or distractions.
• Always be aware of the worksite where open burning is allowed. Airborne sparks or glowing embers may cause fire on
the machine.
• Operations such as logging, mulching, land clearing or landfill operations may cause trash and debris to accumulate on the
machine. Remove debris or trash on a daily or more frequent basis as necessary to prevent fire.
• Always clean trash from the exhaust system compartments. The hot exhaust compartments may cause fire from contact
with flammable material.
• Remove any leaves, wood chips, paper, wood dust or anything that could catch fire accumulated around the engine.

D51EX/PX-22 1-17
SAFETY
AVOIDING DANGEROUS SITUATIONS
When using a dozer for knocking things down, such as trees, make sure
the area is clear of people, animals or objects that may be injured or
damaged.

Do not use a dozer for clearing trees or tall object unless the machine
has a protective cage installed.

Do not let personnel ride on the draw bar or any attachments.

If someone should approach you while you are operating the machine,
stop all operations immediately and signal them not to approach until
the work equipment is lowered to the ground and it is safe for them to
approach. Once they have approached, do not touch any of the machine
controls until they are away from your work area and at a safe distance.

1-18 D51EX/PX-22
 SAFETY
Use extreme caution when near the edge of a cut, ditch, water or any
soft area, as the edge may give way causing the machine to slide or
rollover.

When climbing a steep incline always move slowly in the lower speed
ranges. If the operator tries to go too fast on a hill the bulldozer may
slide causing a possible loss of control or a rollover.

Be careful when cresting the top of a hill or edge way. Always proceed
slowly when approaching these areas to avoid being jolted once the
machine breaks over the fulcrum point. Failure to do so may result in
damage to the machine or severe injury to the operator.

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.

Do not try to make a turn with the dozer on a steep slope. This could
cause the dozer to slide down the slope or possibly rollover.

D51EX/PX-22 1-19
SAFETY
If you must tow a load on a downhill grade make sure to keep the dozer
in low gear. Do not coast a bulldozer while towing a load down hill. The
chances of the load jackknifing with the dozer become greater as the
speed of the machine increases.

When climbing down a slope, select a gear speed which actuates the
engine brake and press the brake pedal, when necessary.

HIGH VOLTAGE LINES

• When working or traveling in an area where clearances are a
problem, travel at a slow cautious speed.
• If you are not sure of your clearances, request the aid of another
person who can guide or warn you if you get too close to objects.
• Be aware of the dangers when working around overhead electrical
lines, high humidity may pose an electrical hazard even if your
machine clears the overhead power lines.
• If your machine should come in contact with overhead electrical
lines, stop the machine and remain on the machine until the power
company clears the lines and it is safe to get off or move the
machine.
• If low power lines pose a greater hazard, ask the power company to remove the lines until your work is finished.

Cable Voltage Min. Safe Distance

6.6kV 3m 10 ft.
66.0kV 5m 16 ft.
275kV 10 m 33 ft.

1-20 D51EX/PX-22
 SAFETY
RULES FOR ROAD TRAVEL
Traveling with your machine may pose some hazards. When traveling, always travel in a safe manner and remain alert at
all times a safety conscious operator is the most important insurance when traveling with the machine. Below are several
situations and information the operator should be aware of.

PRECAUTIONS WHEN TRAVELING

• When traveling on level ground, keep the work equipment at a

height of 40 to 50 cm (16 to 20 in) from the ground.
• When traveling on flat ground, the decelerator pedal can be used to
stop the machine. However, this does not mean that the brake is
applied. On slopes, even if the decelerator pedal is depressed and
the engine speed is reduced, the machine may move, so be
particularly careful.

• 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.
• When traveling or carrying out operations, always keep a safe
distance from people, structures, or other machines to avoid coming
into contact with them.
• 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.
• When operating in tunnels, under bridges, 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.
• 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.
• 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.
• If the machine moves with only either side of the blade loaded, its tail may swing. Take care.

USING BRAKES
Use the deceleration pedal or speed shift switch to adjust the speed. If the brake pedal is suddenly depressed, the mechanical
brake is applied to stop the machine suddenly, but this is dangerous if the machine is traveling too fast.
When traveling downhill, set the travel speed to a low speed and use the engine as a brake.

D51EX/PX-22 1-21
SAFETY
RULES FOR TRAVELING IN REVERSE
Traveling in reverse may pose several hazards. Below is a list of some
basic rules to follow when traveling in reverse.
• Be sure the area behind you is clear of people or objects.
• Before moving your machine, sound the horn to warn others in your
area you are moving.
• When operating in areas that may pose a hazard or has poor
visibility, designate a person to direct your movements.
• Do not rely totally on you machines mirrors, keep in mind there are
blind spots when using the mirrors.

TRAVELING ON ICY OR SNOW-COVERED SURFACES

If the ground is icy or covered with snow, the response of the machine to the movements may not be as precise as expected. To
limit the risk resulting from reduced maneuverability, proceed as follows:
• Travel at a slow safe speed. Avoid rapid accelerations or braking.
• Remember your stopping distances are reduced during slippery conditions.

WORKING ON LOOSE OR UNSTABLE GROUND

To limit the risk when working in these areas:
• Avoid operating the machine to close to the edge of a cliff, open trenches or ditch lines. These areas may collapse under
the weight of your machine causing serious damage to the machine or injury to the operator.
• Keep in mind after a heavy rain or thaw, the surface conditions become worse and less stable.

TRAVEL ON SLOPES
Traveling on slopes may pose a hazard. In order to prevent tipping
the machine or losing control, it is important to follow some basic
simple rules.
.
Never turn the ignition key off when traveling up or down a slope.
If the engine should stop, apply the brakes and stop the machine
immediately. Lower all work equipment to the ground immediately.

When traveling over rough ground, travel at a slow controllable

speed.

Always travel straight up or straight down a slope, traveling at an

angle on a slope may cause the machine to tip or possibly rollover.

1-22 D51EX/PX-22
 SAFETY
PARKING THE MACHINE
When parking the machine it is important to follow several basic
safety rules. Keep in mind you are responsible for the security of the
machine when it is parked. Below is a list if some basic rules to
follow when parking your machine.

1. Always park the machine on a flat level location away from

moving equipment, pedestrians or traffic.

2. Lower all work equipment on to the ground or lock it in place and

neutralize all controls.

3. Lock all areas on the machine equipped with a locking security

feature.

4. Remove the ignition key, set the parking brake in the “PARK”
mode and lock the controls.
See “LEAVING OPERATOR’S COMPARTMENT” on page 1-14.
Be sure all access panels, cab, fuel and oil tanks are locked and
secure to prevent tampering with the machine while unattended.

5. Avoid parking the machine on a slope of any kind. If you must

park on a slope, park with the bucket facing down the slope and
the wheels blocked to prevent any movement of the machine.

D51EX/PX-22 1-23
SAFETY
PRECAUTIONS DURING MAINTENANCE OPERATIONS
All maintenance performed on this machine must only be performed by trained and authorized personnel. When performing
maintenance it is important to follow the outlined maintenance procedures and safety information outlined in this manual and
in the Shop Manual for this machine.

WARNING TAGS
Before performing any maintenance operations on this machine,
position the machine on level and firm surface.

Lock the equipment controls, remove the ignition key and tag the
work equipment control lever.

Alert all personnel in your area that the machine is down for
maintenance. If necessary, tag the machine around specific points to
warn others that this machine is down for maintenance.

If the machine will be down for maintenance for a long period of time,
be sure to check to see if the warning tags are still in place before you
start your repair procedures.

EQUIPMENT STORAGE
Always store optional or extra work equipment in a safe and secure
location.

Store equipment in such a way that it cannot fall or cause injury to

others.

1-24 D51EX/PX-22
 SAFETY
WORKING UNDER THE MACHINE
Always use approved jack stands to support the machine when
performing maintenance under the chassis.

Never rely on hydraulic jacks or the machine’s work equipment to

support the machine when working under or on the machine.

Always lower the work equipment to the ground after raising the
machine for repairs.

USING DROP LAMPS

Use only approved explosion-proof lamps when checking fuel, oil, or
batteries. Non-approved lamps can cause an explosion or fire.

KEEPING THE MACHINE CLEAN

Never use flammable liquids to clean your machine. Use only approved
non-flammable cleaning solvents to clean parts or the machine itself.

Avoid using high pressure steam cleaners or caustic soaps to wash the
machine if possible. Steam cleaning or using caustic soaps may damage
paint, wiring or sensitive electrical components.

Never use high pressure water or flood the inside of the operator’s cab.
Doing so may damage sensitive electrical components.

When pressure washing, use high pressure hot water and mild grease
cutting soaps.

Always grease the machine after cleaning to push any water out of the pivot point connections.

Remove trash daily or more often as necessary. Never allow trash to accumulate on the machine.

D51EX/PX-22 1-25
SAFETY
RUNNING THE MACHINE DURING MAINTENANCE
If during maintenance the engine must be run, be sure all work equipment is locked.
Have someone remain in the operator’s seat while the engine is running, in case the engine must be shut down quickly.

RULES FOR REFUELING THE MACHINE

Always clean up any spills. Grease, fuel, oil or coolant spills can pose a
trip hazard if not mopped up immediately.

Be sure you are adding the correct fluids to the proper location. Mixing
fluids can cause damage to internal components.

When refueling or adding any fluids, be sure you are in a well ventilated
area.

Never smoke or allow open flames near you while you are refueling the
machine.

Never mix gasoline with diesel fuel. Gasoline is extremely flammable

and could cause an explosion.

Do not fill the fuel tank completely, leave room for the fuel to expand.

COOLING SYSTEM PRECAUTIONS

Never add coolant to a hot or warm engine. Always allow the engine
time to cool down completely before opening the radiator cap.

Never dump used coolant on the ground, in a lake, stream or in a sewer

system. EPA Law requires these fluids to be captured and recycled
properly. Failure to do so is in violation of the law.

WORK UNDER THE MACHINE

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.

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 are touched by accident, or
there is damage occurring to the hydraulic piping, the work equipment
or the machine will suddenly drop. This is extremely dangerous. Never
work under the work equipment or the machine.

1-26 D51EX/PX-22
 SAFETY
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.
If hard metal parts such as pins, 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.
Always check that there is no one in the surrounding area.

TURN THE BATTERY DISCONNECT

SWITCH TO THE OFF POSITION
In the following events, follow the switch off procedures as described
below.
First turn the starting switch to the OFF position, wait over on minute, then turn off the battery disconnect switch, and take out
the battery disconnect switch key before;
• Storing the machine for one or more months;
• Repairing electrical systems;
• Performing electric-welding;
• Handling batteries;
• Replacing fuses or fusible links

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 electrocution when carrying out welding, so never allow any unqualified personnel to perform
the procedure.

ENGINE SYSTEM HIGH VOLTAGE

The machine is equipped with an electronically controlled engine, high
voltage is used to control fuel injection, (110 - 130 V) for the fuel
injector drive. Never handle the engine wiring harness while the engine
is running, tamper with or modify this circuit, severe injury may result
due to the high voltage and amps in the circuit. Always use caution
when working around this circuit.

D51EX/PX-22 1-27
SAFETY
BATTERY PRECAUTIONS

Do not try to connect/disconnect battery cables or jump start

machine with battery top cover in place. Always remove the
battery top cover before performing these tasks. Failure to
do so may result in injury or death.

When removing the battery cables, first turn the starting switch to the
OFF position, then turn off the battery disconnect switch, and take out
the battery disconnect witch key. Then, begin cable removal at the
ground (negative (-)) cable side.

When using jumper cables to start the machine as shown below, hook the positive (+) jumper up first, then the negative (-)
jumper last to a remote location on the chassis.

Never use a welder or a machine with a higher voltage system to jump start the machine. Using a
higher voltage to jump-start a machine may damage the machines electrical system or cause an
unexpected explosion or fire. Always jump-start a machine with equal voltages.

1-28 D51EX/PX-22
 SAFETY
STARTING THE MACHINE
Never try to start the machine by tampering or shorting the starter
terminals. Accidental movements of the machine could cause injury or
even death.

Always start the machine seated in the operators cab using the ignition
switch.

See “STARTING THE ENGINE” on page 2-77.

HIGH PRESSURE HOSES

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.
Do not carry out any inspection or replacement work when the hydraulic
system is under pressure.
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 carrying out inspection, wear safety glasses and leather gloves.
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 area with clean water, and consult a doctor immediately
for medical attention.

HANDLING HIGH-PRESSURE HOSES

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 torque. 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.
• Damaged or leaking hydraulic fitting.
• Frayed or cut covering or exposed reinforcement wire layer.
• Covering swollen in places.
• Twisted or crushed movable portion.
• Foreign material embedded in covering.

D51EX/PX-22 1-29
SAFETY

PRECAUTION FOR HIGH FUEL PRESSURE

High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection 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.

HIGH TEMPERATURE AREAS

When you stop the machine at the end of a job, remember the engine
coolant, oil, all engine parts, exhaust stack and the hydraulic system are
still hot and under pressure. If you attempt to drain engine coolant,
hydraulic fluid, or engine oil under these conditions, you expose
yourself to various dangers, including the risk of serious burns.

Carry out maintenance procedures described in this manual only when

the machine has had time to cool down.

ROTATING PARTS
Take particular care near rotating parts. Keep your body at a safe
distance.

If hands, clothing, or tools become entangled in the fan blades or fan

belt, severe injury may result. Keep well away from all rotating parts.

DISPOSAL OF WASTE MATERIALS

Never dump waste fluids in a sewer system, on the ground, in rivers, etc.

Always drain fluids from your machine into the appropriate containers.
Never drain fluids directly onto the ground.

1-30 D51EX/PX-22
 SAFETY
Obey appropriate laws and regulations when disposing of harmful
objects such as oil, fuel, filters, batteries, coolant, brake fluid and
hydraulic oil. Always recycle whenever possible. Failure to do so may
result in fines or punishment.

USING HIGH-PRESSURE GREASE TO

ADJUST TRACK TENSION
Grease is pumped into the track tension adjustment system under high
pressure.

If the specified procedure for maintenance is not followed when making

adjustment, grease drain plug (1) may fly out and cause serious injury or
property damage.

When loosening grease drain plug (1) to loosen the track tension, never
loosen it more than one turn. Loosen the grease drain plug slowly.

Never put your face, hands, feet, or any other part of your body close to grease drain plug (1).

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.

ACCUMULATOR
This machine may be equipped with an accumulator charged with
high-pressure nitrogen gas. Before servicing the accumulator,
observe the following precautions:
• Do not dissemble the accumulator.
• Do not expose the accumulator to high heat or an open flame.
• Do not weld on the accumulator.
• Do not drill or cut the accumulator.
• Do not strike or crush the accumulator.
• When replacing or disposing of the accumulator, always release
the nitrogen pressure from the chamber.

D51EX/PX-22 1-31
SAFETY
CRITICAL PARTS
Periodically some parts must be replaced for safety reasons. Even if
these parts seem to be in good condition and operating
properly they may fail at some point causing possible injury to the
operator or pedestrian. Listed are some of the systems
containing these components that may fail under extended use:
• Fuel supply and delivery hoses.
• Hydraulic system: main delivery hoses and tubing.
• Hydraulic hoses: all the hoses that feed and return the hydraulic
fluid to and from the work equipment.

For additional information: See “PERIODIC REPLACEMENT OF

SAFETY CRITICAL PARTS” on page 3-17.

1-32 D51EX/PX-22
 SAFETY
TRANSPORTING THE MACHINE
Before transporting the machine be sure what you are using to transport the machine is capable of supporting the weight of the
machine. Be sure it is wide enough and rated for the load.

LOADING AND SECURING THE MACHINE

1. Be sure the area you will be loading the machine in is flat and dry.
2. Check the ramps and support surface for damage, week spots, missing boards or excess wear. If these surfaces look
unsafe, too weak or unstable do not load the machine. Be sure the loading equipment and transportation equipment are in
good condition and rated for your load.
3. Locate the tie down and transportation brackets on the machine. Be sure they are in good condition.
4. When getting ready to load the machine be sure the loading ramps are no higher than 15°.
5. Position the machine squarely with the ramps. Raise the dozer blade high enough to clear all surfaces.
6. Travel up the ramp at a slow speed in low range. Position the blade (1) facing forward and travel straight up the ramp.
7. Lower blade (1) and ripper (2) down on the trailer bed set the machine in neutral and set the parking brake.
8. Turn the ignition key off and remove the key.
9. Place blocks (3) under front and rear tracks.
10. Cover stack (5) to keep water from entering the engine.
11. Secure the machine with tie-downs/chains (4) at the anchor points shown in illustration.

D51EX/PX-22 1-33
SAFETY

TOWING THE MACHINE

Serious injury or death could result if a disabled machine is towed
incorrectly or if there is a mistake in the selection or inspection of the
wire rope.
For towing method, See “TOWING THE MACHINE” on page 2-118.
• Always wear leather gloves when handling wire rope.
• Connect a wire rope to the hitch or front tow hook indicated with
the arrow in the diagram to the right or below.
• During the towing operation, never stand between the towing
machine and the machine being towed.
• Never tow a machine on a slope.
• Never pull the towing equipment up or insert a pedestal.
• Never use a wire rope which has cut strands (A), reduced diameter
(B), or kinks (C). There is danger that the rope may break during
the towing operation.
• If the engine stops or the oil pressure in the brake circuit lowers
because of a trouble in the brake valve solenoid, the brake applies
and the machine cannot move. To move the machine in this case,
the oil pressure in the brake circuit must be raised to the
specified level with a special device. Ask your Komatsu distributor.
•
•
•
•

1-34 D51EX/PX-22
 OPERATION 2

D51EX/PX-22 2-1
OPERATION
GENERAL VIEWS

VIEW OF MACHINE

1. Blade 5. Track shoe 9. Front idler

2. Angle cylinder 6. Drive sprocket 10. Dozer frame
3. Front grill 7. Track frame
4. Cab (integrated with ROPS) 8. Lift cylinder

2-2 D51EX/PX-22
 OPERATION
VIEW OF CONTROLS AND GAUGES

D51EX/PX-22 2-3
OPERATION

1. Work equipment lock lever 15. Temperature control switch (Left side console)
2. Feet heater 16. Blower switch (Left side console)
3. Parking brake lever 17. Air conditioner mode switch (Left side console)
4. Cab light (machines with cab) 18. Brake pedal
5. Wiper switches (machine with cab) 19. Deceleration pedal
6. Radio (machine with cab) (optional) 20. Ripper control lever (Right side console)
7. Lamp switch 21. Horn button (Right side console)
8. Fan rotation selector switch 22. Blade control lever
9. Buzzer cancel switch 23. Ignition switch
10. Information switch 24. Heater switch (feet heater)
11. Travel lever 25. Shift mode switch
12. Fuel control dial (Left side console) 26. Reverse travel speed set switch
13. Cigarette lighter (Left side console) 27. Monitor panel
14. Electrical accessory plug (Left side console)

2-4 D51EX/PX-22
 OPERATION
MACHINE MONITOR SYSTEM
The monitor system is the main control panel of the machine. This unit monitors all the functions relating to the machines
operating system. It is important for the operator of this machine to study the monitor and become familiar with all the
functions in order to achieve maximum performance from the machine. Failure to do so may lead to poor performance or
premature failure of the machine.

MONITOR BEZEL LAYOUT

1. Engine coolant temperature gauge 10. Engine intake air preheat lamp
2. Hydraulic oil temperature gauge 11. Charge filter clog caution lamp
3. Display panel A (speed range, set travel speed, shift mode) 12. Warning lamp
4. Fuel gauge 13. HST charge pressure caution lamp
5. Battery charge caution lamp 14. Fan operation confirmation lamp
6. Engine oil pressure caution lamp 15. Maintenance caution lamp
7. Engine coolant temperature caution lamp 16. Air cleaner clog caution lamp
8. Water separator lamp 17. Display panel B (multi-information)
9. Hydraulic oil temperature caution lamp

D51EX/PX-22 2-5
OPERATION
BASIC OPERATION OF MONITOR PANEL

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 meaning of the displays.

A. Emergency items B. Caution items C. Meter group

D. Warning lamp E. Switches

1. Lamp switch 2. Fan rotation selector switch 3. Buzzer cancel switch

4. Information switch 5. Reverse travel set switch 6. Shift mode switch
7. Heater switch (feet heater) 8. Ignition switch 9. Preheat pilot lamp
10. Fan operation confirmation lamp 11. Display panel B (multi-information)

2-6 D51EX/PX-22
 OPERATION
CHECK MONITOR SYSTEM

l Stop the machine on level ground and carry out the monitor check.

l Stop the engine, then turn the ignition switch to the ON position and check to be sure lamps light up
for approx. 2 seconds. If they do not light up, please ask your Komatsu distributor to carry out
inspection.

The monitor check cannot be carried out until at least five seconds has
passed after the engine was stopped.
When carrying out the checks before starting, use the monitor system
check.
1. Turn the ignition switch to the ON position.
2. Check to be sure monitor liquid-crystal display and the lamps all
light up for two seconds, that the alarm buzzer sounds for 2
seconds, and that “KOMATSU” is displayed for 3 seconds on
display panel (B) (multi-information) (1).
A. After two seconds, the current status of the machine is
displayed on liquid-crystal display (2).

B. After two seconds, the lamp portion (3) goes out.

C. After three seconds, the operating mode is displayed on display panel (multi-information) (1).

Remark
The following cases do not indicate any problem:
If the preheating is activated in cold weather, engine
preheating pilot lamp (4) does not go out until preheating is
completed.
When the replacement interval is reached for the oil and filter,
maintenance caution lamp (5) lights up or flashes for 30
seconds, the item to be replaced is displayed on display
panel B (multi-information) (1).

D51EX/PX-22 2-7
OPERATION
MONITOR CHECK ITEMS
Below is a list of monitor items that must be checked during start-up and operation of the machine. It is important to
understand what these alerts mean and how to deal with them. Failure to do so may lead to a system failure within the
machine.

EMERGENCY ALERTS

If the monitor lights up red, stop the engine immediately or run at low idle, check applicable location, then
perform necessary actions.

These items should be observed while the engine is running. If there is a problem, the indicator lamp for the abnormal location
lights up red, the warning lamp (A) lights and buzzer sounds. If this happens perform actions immediately.

1. Engine oil pressure 2. Engine coolant temperature 3. Hydraulic oil temperature

caution lamp caution lamp caution lamp
4. HST charge pressure caution lamp 5. Charge filter clog caution lamp (A) Warning lamp

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.
The alarm buzzer sounds, when the ignition switch is turned to ON
immediately after the engine oil has been changed. It does not indicate a
problem.

2-8 D51EX/PX-22
 OPERATION
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 idle speed until
the engine coolant temperature indication returns to the green range.

HYDRAULIC OIL TEMPERATURE CAUTION LAMP

This lamp (3) warns the operator that the hydraulic oil temperature has
gone up.
If it flashes, run the engine at low idle until the hydraulic oil temperature
gauge indication returns to the green range.

HST CHARGE PRESSURE CAUTION LAMP

This lamp (4) warns the operator that the HST charge pressure has
dropped.
If it flashes, stop the machine and check for the cause of the drop in the
charge pressure.

CHARGE FILTER CLOG CAUTION LAMP

This lamp (5) warns the operator that the HST charge filter is clogged.
If it flashes, stop the machine, check for the cause of clogging, and
replace the filter element with a new part.

D51EX/PX-22 2-9
OPERATION
WARNING ALERTS

If the warning monitor lights up red, stop operations as soon as possible and carry out inspection and
maintenance at the applicable location. If the warning is ignored, it may lead to failure.

These are items that should be observed while the engine is running. If any abnormality occurs, the screen displays the item
that needs immediate action.
If there is an abnormality, the indicator lamp for the abnormal location lights up red.

1. Battery charge caution lamp 2. Air cleaner clog caution lamp

3. Water separator lamp 4. Maintenance caution lamp

BATTERY CHARGE CAUTION LAMP

This lamp (1) indicates a problem in the battery charging system while
the engine is running.
If the monitor lamp flashes, check the alternator drive belt.
Remark
This monitor lamp lights when the ignition switch is turned to
ON immediately after the engine is started or immediately
before the engine is stopped. It does not indicate a problem.

2-10 D51EX/PX-22
 OPERATION
AIR CLEANER CLOGGING CAUTION LAMP
This lamp (2) warns the operator that the air cleaner is clogged.
If it flashes, stop the engine, and check or clean the air cleaner.
For details, See “ENGINE AIR FILTER” on page 3-23.

WATER IN FUEL LAMP

This lamp (3) warns the operator that there is water accumulated inside
the water separator.
If it flashes, stop the engine and drain the water from the water
separator.
For details, See “DRAINING THE PRE-FILTER” on page 2-64.

Remark
The water separator forms one unit with the fuel pre-filter. It is
at the bottom of the fuel pre-filter and can be removed.

MAINTENANCE CAUTION LAMP

This lamp (4) lights up for approx. 30 seconds after the ignition switch
is turned to the ON position if the filter or oil replacement interval has
been reached.
l Flashes: 30 hours remaining to replacement
l Lights up: replacement time has passed
After replacing the indicated filter or oil displayed on display panel B
(multi-information), reset the interval. For details, see See “USING
MAINTENANCE MODE” on page 2-27.
The lamp goes out.

D51EX/PX-22 2-11
OPERATION
CONSOLE CONTROL SWITCHES
In addition to the monitor switches, these control switches are located on the left and right console but work in conjunction
with the monitor system.

SWITCH LAYOUT VIEW

1. Lamp switch 8. Ignition switch

2. Fan rotation selector switch (See page 2-17)
3. Buzzer cancel switch
4. Information switch
5. Reverse travel speed set switch (See page 2-17)
6. Shift mode switch (See page 2-17)
7. Heater switch (standard on machines equipped with cab)
(optional on machines equipped with canopy
9. Horn switch
10. Wiper switch (machines equipped with cab)
11. Cab lamp switch (machines equipped with cab)
12. Cigarette lighter (machines equipped with cab)
13. )Accessory socket (machines equipped with cab)

LAMP SWITCH
This switch (1) lights up the front and rear lamps.
l Center position: OFF.
l F position: Front lamps light.
l FR position: Front and rear lamps work together.
The switch also lights up.

2-12 D51EX/PX-22
 OPERATION
BUZZER CANCEL SWITCH
This switch (3) is used to operate display panel B (multi-information) or
to stop the alarm buzzer.
When the switch is released, it returns automatically to the center
position.
l When display panel B (multi-information) is in the operating mode
l If the alarm buzzer sounds press the n portion of the switch to
stop the buzzer.
l If the switch is pressed, the screen switches to the mainte-
nance mode.
l When display panel B (multi-information) is in the maintenance
mode.
n position: Cancel or return to operation mode.
position: Confirms selection or selected item.
For details, See “USING MAINTENANCE MODE” on page 2-27.

Remark
When the ignition switch is in the OFF position, press the to display the service meter on control panel B
(multi-information).

INFORMATION SWITCH
This switch (4) is used to operate display panel B (multi-information).
When the switch is released, it returns automatically to the center
position.
l When display panel B (multi-information) is in the operation
mode, press the switch to < or > to switch the display to service
meter or engine speed.
l When display panel B (multi-information) is in the maintenance
mode.
It is used to move between modes, between items, to move the cursor, or
to change values.
For details, See “USING MAINTENANCE MODE” on page 2-27.

HEATER SWITCH
(Standard on machines equipped with cab).

(Optional on machines equipped with canopy).

l Switch (A) is the heater select switch.

l Switch (B) is the blower switch.
l Switch (C) is the temperature control.

D51EX/PX-22 2-13
OPERATION
FEET HEATER
With switch (7) the feet heater can be used. This feature is standard on
machines equipped with cab.

(Optional on machines equipped with canopy).

The location of the feet heater is (A).

For operation of the feet heater: See “FEET HEATER” on page 2-48.

IGNITION SWITCH
The switch (8) is used to start and stop the engine.
l OFF position:
At this position, the ignition switch key can be inserted and removed.
When the switch is turned to this position, all the electric circuits are
turned off and the engine stops.
l ON position:
In this position, electric current flows in the charging and lamp circuits.
Keep the ignition switch key at the ON position while the engine is
running.
l START position:
This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately after the
engine has been started. The key will return to ON position when released.
l HEAT position:
This is the position to preheat the engine for cold weather start. If the key is kept at the HEAT position, the engine
pre-heating pilot lamp will light up.
For details. See “COLD WEATHER STARTS” on page 2-80 in OPERATION portion.

2-14 D51EX/PX-22
 OPERATION
HORN SWITCH
The horn sounds when the button (9) at the rear of the blade control
lever at the right side of the operator's seat is pressed.

WIPER SWITCH
(Machines equipped with cab).
This (10) activates the wipers.
The wiper switches are as follows:
l (A) Left door window (LH).
l (B) Front window (FF).
l (C) Right door window (RH).
l (D) Rear window (RR).
l (E) Intermittent switch (INT).
(for left and right door windows).
l Wiper only.
If this is switched to the center position, the wiper will start.

l Wiper and window washer

If this switch is pressed beyond the center position while the wiper is
working, water will be sprayed on the window. The switch will return to
the center position when released.

D51EX/PX-22 2-15
OPERATION
l If the intermittent switch is turned ON the movement of the door
wipers will be intermittent.

CAB LAMP SWITCH

(Machines equipped with cab)
This switch (11) is used to light up the cab lamp.
l OFF position: Lamps are out.
l ON position: Lamps light up.

CIGARETTE LIGHTER
(Machines equipped with cab).
This (12) 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.
If the cigarette lighter is removed, the socket can be used as a power
source.
Remark
This cigarette lighter is 24V. Do not use it as the power
source for 12V equipment. If it is used so, the equipment may
fail.
The capacity of the cigarette lighter is: 120W (24V x 5A).

ACCESSORY SOCKET
(Machines equipped with cab).
This (13) is used for low amp 12V equipment.
Remark
The capacity is 144W (12V x 12A).

2-16 D51EX/PX-22
 OPERATION
METER DISPLAY

1. Engine coolant temperature gauge 6. Shift mode switch

2. Hydraulic oil temperature gauge 7. Engine intake air preheat pilot lamp
3. Display panel A (Speed range, set travel speed, 8. Display panel B (Multi-information)
shift mode indicator)
4. Fuel gauge 9. Fan rotating selector switch
5. Reverse travel speed set switch A. Fan operation confirmation lamp

ENGINE COOLANT TEMPERATURE GAUGE

Remark
If the coolant temperature gauge often enters red range (C),
check the radiator for clogging.
Gauge (1) indicates temperature of the engine coolant.
If the temperature is normal during operation, green range (B) is
indicated.
If red range (C) is indicated during operation, move the fuel control
lever to lower engine speed to approx. 3/4 of the full speed, and run until
the coolant temperature enters green range (B).
If red range (C) lights up during operation, and the engine coolant
temperature caution lamp flashes and the alarm buzzer sounds, stop the machine, run the engine at low idle, and wait for the
coolant temperature to return to the green range (B).
l (A): White range
l (B): Green range
l (C): Red range

D51EX/PX-22 2-17
OPERATION
HYDRAULIC OIL TEMPERATURE GAUGE
Remark
If the hydraulic oil temperature gauge frequently enters red
range (C), check for clogging of the oil cooler.
This meter (2) displays the oil temperature in the pump suction piping.
Green range (B) should be lighted up during normal operations.
If the red range (C) lights up during operation, move the fuel control
lever to lower engine speed to approx. 3/4 of the full speed, reduce the
load and run until the oil temperature enters the green range (B).
If red range (C) lights up during operation, and the HST oil temperature
caution lamp flashes and the alarm buzzer sounds, stop the machine, run
the engine at low idle, and wait for the oil temperature to go down to the green range (B).
l (A): White range
l (B): Green range
l (C): Red range

DISPLAY PANEL (A)

This display (3) shows the speed range, set travel speed, and shift mode.
l When quick shift mode is selected, pilot lamp (C) on display
panel lights up.
l When variable shift mode is selected, pilot lamp (D) on display
panel lights up.

Use shift mode switch (6) to change the shift mode.

l Position (A): Quick shift mode, press the switch to the position
(A) to select the quick shift mode.
l Position (B): Variable shift mode, press the switch to the
position (B) to select variable shift mode.

2-18 D51EX/PX-22
 OPERATION
QUICK SHIFT MODE
The travel speed is set to the travel speed that matches the general
operating load. Operation is easy:
l Each time the UP switch on the travel lever is pressed, the speed
switches 1st Þ 2nd Þ 3rd
l Each time the DOWN switch on the travel lever is pressed, the
speed switches 3rd Þ 2nd Þ 1st.

The direction of travel (E) and speed range (F) are displayed in the
speed range display at the bottom right.
l (E)
l F: Forward
l R: Reverse
l N: Neutral
l P: Parking brake lever is in LOCK position
l (F)
l 1: 1st.
l 2: 2nd.
l 3: 3rd.

H Example: F1 is displayed for FORWARD first.

l The outer bar graph (G) lights up to match the selector speed range when traveling forward.
l The inner bar graph (H) lights up to match the selected speed range when traveling in reverse.
l When the ignition switch is turned from OFF to ON, the speed range is set by default to 1st.

VARIABLE SHIFT MODE

The travel speed can be set in 20 stages from 0.8 km/h (0.5 MPH) to 9.0
km/h (5.6 MPH).
In particular, the minimum travel speed is set low so that work such as
loading the machine onto a trailer or traveling over rough places on the
road surface can be carried out more safely.
Furthermore, it is possible to adjust the optimum travel speed over a
wider range for work such as plowing or winch operations.
l Each time the UP switch on the steering, forward-reverse, gear shift
lever is pressed, two segments on the bar graph around the outside
circumference light up and the set travel speed increases by
approximately 0.4 km/h (0.2 MPH).

D51EX/PX-22 2-19
OPERATION
l If the UP switch on the steering, forward-reverse, gear shift lever is
kept pressed, the segments on the bar graph around the outside
circumference light up in turn. When the switch is released, the
speed range is set at that position.
l To reduce the set speed, press the DOWN switch on the steering,
forward-reverse, gear shift lever in the same way.
l Direction of travel is displayed at (E) on the speed range display at
bottom right and the set travel speed is displayed on bar graph (G)
around the outside circumference.
l Nothing is displayed in (F).

l (E)
l F: FORWARD
l R: REVERSE
l N: Neutral
l P: Parking brake lever is at LOCK position

2-20 D51EX/PX-22
 OPERATION
l When the ignition switch is turned from the OFF position to the ON position, the speed range is set by default to 1st.
l If the mode is shifted from variable shift mode to quick shift mode, the speed range is set to the nearest speed range (1st,
2nd, or 3rd).
l See the chart below for details of the lighting up of bar graph (G) around the outside circumference and the set travel
speed.

Set travel Set travel Set travel

Gauge No. Speed range speed Gauge No. Speed range speed Gauge No. Speed range speed
km/h (MPH) km/h (MPH) km/h (MPH)
1 15 27
0.2 0.8 (0.5) 1.1 3.8 (2.4) 2.2 6.1 (3.8)
2 16 28
3 17 29
0.3 1.0 (0.6) 1.3 4.1 (2.5) 2.3 6.6 (4.1)
4 18 30
5 19 31
0.4 1.5 (0.9) 1.4 4.5 (2.8) 2.4 7.1 (4.4)
6 20 32
7 21 33
0.5 2.0 (1.2) 1.6 4.9 (3.0) 2.6 7.5 (4.7)
8 22 34
9 23 35
0.6 2.4 (1.5) 1.8 5.2 (3.2) 2.7 8.0 (5.0)
10 24 36
11 25 37
0.8 2.9 (1.8) 2.0 5.6 (3.5) 2.9 8.5 (5.3)
12 26 38
13 39
1.0 3.4 (2.1) 3.0 9.0 (5.6)
14 40

REVERSE TRAVEL SPEED INDICATOR

It is possible to choose the reverse travel speed (H) in five stages
according to the nature of the work without changing the forward travel
speed. This means that the reverse travel speed can be obtained simply
by shifting the steering, forward-reverse, gear shift lever. There is no
need to shift gear.
If it is desired to raise the efficiency of dozing work, make the reverse
travel speed faster.
When traveling in reverse on rough ground surfaces or when carrying
out pushing-up work, make the reverse travel speed slower.

l The reverse travel speed is set by pushing reverse travel speed set
switch (5) to the left or right.
l The more it is pushed on to the right, the faster the set travel speed
becomes.
l The more it is pushed on to the left, the slower the set travel speed
becomes.
l The inner bar graph (H) shows the selected reverse travel speed.
l There are five pre-settings for the reverse travel speed.
l When the ignition switch is turned ON, the reverse travel speed is
set in the immediate position. The reverse travel speed is
approximately 20% faster than the forward travel speed.
l With one press of the left side of the switch, the reverse travel speed
becomes the same as forward.
l The reverse travel speed will not exceed maximum speed 9.0 km/hr (5.6 mph).

D51EX/PX-22 2-21
OPERATION
FUEL LEVEL GAUGE
Gauge (4) displays fuel level in the fuel tank.
During normal operation, the green range (B) should be lighted up.
If the red range (A) lights up during operation, add fuel immediately. If
this is not done, the engine speed will become irregular or an error
display will be shown on the monitor.
l (A): Red range
l (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 20 liters (5.28 US gal) of fuel remaining.

REVERSE TRAVEL SPEED SET SWITCH

This switch (5) can be used to set the reverse travel speed to a different
setting from the forward travel speed.
For details. See “REVERSE TRAVEL SPEED INDICATOR” on
page 2-21.
When the switch is released it returns to the center position.

SHIFT MODE SWITCH

Use this switch (6) to switch the shift mode.
For details, See “DISPLAY PANEL (B)” on page 2-23.

When the switch is released it returns to the center position.

ENGINE INTAKE AIR PRE-HEAT PILOT LAMP

Lamp (7) indicated that the engine intake air is being preheated with an
electric heater in cold weather.
When the ignition switch if turned to the “ON” position, the engine
controller will detect the engine coolant temperature and automatically
start the preheat process at lower coolant temperatures.

2-22 D51EX/PX-22
 OPERATION
DISPLAY PANEL (B)
The top and bottom lines “A” and “B” in display panel (8)
(multi-information) display information related to the condition of the
machine.
The content of the display (8) is divided into “OPERATING MODE”
and “MAINTENANCE MODE”. Use the buzzer cancel switch to
switch between the operating mode and maintenance mode.
For details of switching the mode,See “BUZZER CANCEL SWITCH”
on page 2-13
OPERATING MODE (DEFAULT SCREEN)
Use this mode when operating the machine.
Remark
When the ignition switch is turned from the OFF position to the ON position, display panel B (multi-information)
always displays the operating mode.
SERVICE METER
This shows the accumulated operating hours of the machine. Use this display to manage the periodic maintenance inter-
vals.
When the engine is running, the service meter advances, even if the machine is not being operated but the engine is run-
ning. When the engine is running, the hourglass icon on the side of the meter lights up to show that the service meter is
advancing. The meter advances 0.1h every 1/10 hour, regardless of engine speed.
BOTTOM LINE (B): NO DISPLAY OR ENGINE SPEED
Use the information switch to display engine speed. for details "INFORMATION SWITCH (PAGE -13)"

ACTION CODE
An action code is displayed if any problems occur on the machine.
If this should happen, carry out any maintenance required on the
machine."MONITOR PANEL (PAGE -126)"
ITEM TO BE REPLACED
When replacement interval is reached for oil filter, item to be
replaced is displayed. For details, "USING MAINTENANCE
MODE (PAGE -27)"

MAINTENANCE MODE
This displays various types of information related to maintenance
of the machine.
For details, See “USING MAINTENANCE MODE” on page 2-27.

D51EX/PX-22 2-23
OPERATION
FAN ROTATION SELECTOR SWITCH
Use switch (9) to select the direction of rotation for the cooling fan:

1. Stop the engine and set the ignition switch to the “ON” position
when switching the direction of rotation for the fan. When the
switch is released, it will return to the center position.
l (O) Position: Rotation in normal direction
2. Press the switch to this position to select normal direction. Fan
operation confirmation lamp (A) goes out. The cooling air is
pushed out the rear of the radiator grill. The fan rotates at speed to
match the cooling system temperature to conduct efficient cooling
l (|) Position: Cleaning (reverse rotation)
1. Press the switch to this position to select cleaning mode. Fan
operation confirmation lamp (A) lights up. The fan rotates in the
opposite direction from normal. In addition, it rotates at high speeds
regardless of cooling system temperature. Use this mode for
cleaning radiator fins. For details. See “CLEANING BY ROTAT-
ING COOLING FAN IN REVERSE DIRECTION” on page 3-43.

Remark
If the engine not running, even if the fan selector switch is
operated, the direction of rotation of the fan will not change.
The fan operation confirmation lamp (A) will flash several
times to inform the operator that the direction of rotation of
the fan has not been changed.
When fan operation confirmation lamp lights up and the fan is rotating in the cooling mode, the machine does
not travel even if the travel lever is operated to FORWARD of REVERSE positions. This is to protect the
radiator. To travel, turn the ignition switch to the off position once, and then turn the ignition switch to the OFF
position once, and then to the ON position once again, after making sure that the fan operation confirmation
lamp (A) has gone OFF.
If the cooling fan is rotating in the cleaning mode, (rotating in the opposite direction) even if the ignition switch
is turned to the OFF position, the electric power is not switched off immediately in order to protect hydraulic
circuit.

2-24 D51EX/PX-22
 OPERATION
WARNING LAMP VIEW

WARNING LAMP (1)

(Red)
Remark
If alarm buzzer sounds, stop work immediately and perform
inspection and maintenance of the appropriate point.
This lamp (1) flashes when the caution lamp flashes and when the part
of an action code is displayed on (multi-information) display panel B.
When the warning lamp (A) of an emergency warning item flashes, or
when the part of an action code is displayed, the alarm buzzer sounds
continuously at the same time.

D51EX/PX-22 2-25
OPERATION
The lamp goes out or stops flashing.

USING FAILURE CODE DISPLAY

If action code is displayed on (multi-information) panel B, perform the following to display the code:
(For details of action code display, See “MONITOR PANEL” on page 2-126).

An example of an action code is given on (multi-information) display

panel B.

To display the failure code, press the > switch.

The content of the display is as follows:
l Position (1); Failure code displayed.
l Position (2): Controller that detected failure code is displayed.

Code Controller detecting failure code

MON : Machine monitor panel
HST : HST controller
ENG : Engine controller

l Position (3): Message is displayed.

If there is more than one failure code, to display the codes press the > switch to advance the information.
If no operation is carried out for 30 seconds, the screen will return to the action code display screen.

2-26 D51EX/PX-22
 OPERATION
USING MAINTENANCE MODE
To switch from the operation mode to the maintenance mode, press the
switch (3) to the . The screen will switch to the maintenance mode.
On the first screen, the oil and filter maintenance mode is displayed.

EXPLANATION OF MODES AND OPERATION

The maintenance mode has the following two sub modes.

Sub mode Function Reference item

Oil or filter replacement time is See “USING OIL AND FILTER MAINTENANCE
Oil filter maintenance mode
displayed MODE” on page 2-29
Adjustment mode Adjusts monitor brightness, etc. See “USING ADJUMENT MODE” on page 2-30

Use information switch (4) and buzzer cancel switch (3) to operate each
mode.

D51EX/PX-22 2-27
OPERATION
METHOD OF SELECTING EACH MODE

2-28 D51EX/PX-22
 OPERATION
USING OIL AND FILTER MAINTENANCE MODE
Remark
This function is only a guideline. If dirty oil or filters are found during daily maintenance, replace them
immediately.
If the monitor panel are replaced, the timer for this function will not work properly. Contact your Komatsu
distributor for replacement.
In the oil and filter maintenance mode, the replacement intervals for oil
and filters are displayed on display panel B (multi-information).
l (1) The item is displayed.
l (2) The time remaining until replacement is displayed.
l (3) The quantity of replacements until now is displayed.

H The display items can be displayed in order by operating the information switch to the left or right (<, >)

Replacement interval
Code Display Item
(hours)
01 ENG OIL Engine oil 500
02 ENG FILT Engine oil filter 500
03 FUEL FILT Fuel filter 1000
41 P FUEL FILT Fuel pre-filter 500
04 HYD FILT Hydraulic oil filter 2000
08 FNL OIL Final drive oil 1000
10 HYD OIL Hydraulic oil 2000
21 HST FILT HST charge filter 2000

D51EX/PX-22 2-29
OPERATION
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 update the replacement history.
Operate the information switch to select (< >), then select YES and
press the switch . The replacement quantity will increase by 1, the
replacement interval will be reset, and the oil, filter change interval
lamp will go out.
When this is done, if the maintenance caution lamp does not go out,
there is another item close to the replacement time, so check that item.
Remark
To return to the maintenance mode without resetting, use the
information switch (< >) to select NO, then press the
switch . .

USING ADJUMENT MODE

With the adjustment mode, the brightness of the panel screen
backlighting and the contrast of the liquid crystal panel can be changed.
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.
This display will be switched to the screen brightness adjustment
display, if the buzzer cancel switch is pressed to the position.

2. The brightness can be adjusted by operating the information switch.

If the n comes closed to “H”, the screen becomes brighter; if it comes
closer to “L”, the screen becomes darker.

> position: n comes closer to “H”

< position: n comes closer to “L”

3. The brightness of the backlight for the LCD gauges may be held
constant by pressing the alarm buzzer cancel switch to the
position. And the screen returns to the previous screen.

2-30 D51EX/PX-22
 OPERATION
1. Adjusting backlighting of display panel B (multi-information)
The diagram on the right is the mode for adjusting the brightness of the
backlighting of the display panel B (multi-information).
On the screen, operate the buzzer cancel switch to switch to the
screen for adjusting the brightness.

2. If the n comes closed to “H”, the screen becomes brighter; if it

comes closer to “L”, the screen becomes darker.
> position: n comes closer to “H”
< position: n comes closer to “L”

3. When the buzzer cancel switch is operated to , the brightness of

the display panel B (multi-information) backlighting is set. And the
screen returns to the previous screen.

Remark
To return to the maintenance mode, operate the buzzer
cancel switch to n.
The brightness of the backlighting of the monitor panel differs according to whether the front lamp is lit or not.
Entering this mode when the front lamps are lit makes it possible to adjust the brightness when the front lamps
are lit. In the same way, entering this mode when the front lamps are not lit makes it possible to adjust the
brightness when the front lamps are not lit.

D51EX/PX-22 2-31
OPERATION
4. Adjusting contrast of liquid crystal display panel B
(multi-information).
The diagram on the right is the mode for adjusting the contrast of the
liquid crystal display panel B (multi-information).
On this screen, operate the buzzer cancel switch to switch to the
screen to adjust the contrast.

5. If the n comes closed to “H”, the screen becomes brighter; if it

comes closer to “L”, the screen becomes darker.
> position: n comes closer to “H”
< position: n comes closer to “L”
6. When the buzzer cancel switch is operated to , the contrast of
the liquid crystal display panel B (multi-information) is set. And
the screen returns to the previous screen.

Remark
To return to the maintenance mode, operate the buzzer
cancel switch to n.

2-32 D51EX/PX-22
 OPERATION
CONTROL LEVERS AND PEDALS
The control levers and pedals are used to travel with the machine and operate the work equipment. It is important to become
familiar with their functions as they relate to the movement of the machine and its work equipment. Failure to do so may lead
to damage to the machine or surrounding property as well as injury to the operator or other personnel.

LEVER LAYOUT VIEW

1. Fuel control dial 5. Blade control lever

2. Travel lever 6. Work equipment lock lever
3. Brake pedal 7. Parking brake lever
4. Decelerator pedal 8. Feet heater unit

LOCK LEVERS

l When leaving the operator's compartment, set the work equipment lock lever securely to the LOCK
position. If the work equipment lock lever is not at the LOCK position and the control levers are
touched by mistake, it may lead to serious personal injury.

l If the work equipment lock lever is not set securely to the LOCK position, the work equipment may
move and cause serious injury. Check that it is in the position shown in the diagram.

l When parking the machine or when carrying out maintenance, always lower the work equipment to the
ground, then set the work equipment lock lever to the LOCK position.

l When parking the machine, always set the parking brake lever in the LOCK position.

l If the parking brake lever is operated, the brake is applied, even when the machine is traveling.
The machine will suddenly stop, so this is dangerous. For this reason, do not operate the parking
brake lever when the machine is moving, except in emergencies.

D51EX/PX-22 2-33
OPERATION
Lever (6) is a device to lock the work equipment control lever. When it
is set to the LOCK position, the movement of the work
equipment is locked.
The blade control lever can move even when the lever is at the LOCK
position, but the control oil pressure of the blade control is locked, so
the blade does not move.
If the blade control lever is at the FLOAT position and the safety lever is
set to the LOCK position, the blade control lever is automatically
returned to the HOLD position.
Lever (7) is the lever to apply the parking brake. The parking brake is
applied when the lever is set to the LOCK position. If the parking brake
lever is not at the LOCK position when the engine is started, the limit
switch is actuated and the engine will not start.

TRAVEL LEVER
This lever (2) is used to select the direction of travel, to carry out
steering, and to carry out counter rotation turns.
l Forward-Reverse shifting
l Position (a): FORWARD.
l Position (b): REVERSE.
l Position N: Neutral.
Move to the front to drive forward; move to the rear to drive in reverse.
l Steering Left - Right.
l Position (c): LEFT TURN.
l Position (d): RIGHT TURN.
If the lever is at the FORWARD or REVERSE position and it is operated to the left or right, the machine will turn in the
direction that the lever is operated. If the lever is operated to the left or right to a position where it becomes heavy, the turning
radius will become smaller.
Remark
When you are steering, if you release the lever, it will return to the center position and the machine will travel in
a straight line. When you are steering, support your hand with the lever guide
to make it easier to carry out the turning operation.
Counter-rotation Turn
When steering the machine, if the lever is operated further from the
heavy point, the left and right tracks will rotate in opposite directions
and the machine will carry out a counter rotation turn.
Gear Shifting
Press the shift switch of the knob of the travel lever to carry out the gear
shifting operation.
l Press the UP switch to shift up.
l Press the DOWN switch to shift down.
When the ignition switch is turned to the ON position, the speed range is
set by default to 1st.
For details. See “DISPLAY PANEL (B)” on page 2-23. If the operating
load increases, the travel speed will slowly decrease and the transmission will shift down. When the load becomes lighter
again, the transmission will shift up to the set travel speed. When the
transmission automatically shifts down, the speed range display does not change.

2-34 D51EX/PX-22
 OPERATION
BLADE CONTROL LEVER
Rotate lever (5) is used to lift, tilt or angle the blade.
After the engine is stopped, while the equipment lock lever is in the
unlocked position an accumulator provides power to operate the blade
spool. This is to allow the blade or ripper to be lowered to the ground
without engine power.
LIFTING CONTROL
l (a) RAISE:
l (b) HOLD: Blade is stopped and held in this position.
l (c) LOWER:
l (d) FLOAT: Blade will move freely according to external
force.
Remark
When released from FLOAT position, this lever will not return
to HOLD position, so it must be moved back by hand.
Before starting the engine, check to be sure blade control
lever is at the HOLD position.
In cold weather, it will take time for the lever to be held at the
HOLD position, so hold the lever by hand at the HOLD
position for at least 1 second.
If the work equipment lock lever is in the locked position, the
accumulator power is not passed to the controller.

TILTING CONTROL
l (b) HOLD: Blade is stopped and held in this position.
l (e) LEFT TILT:
l (f) RIGHT TILT:

Amount of tilt
Machine mm (in)
model
Standard blade Wide blade
D51EX 459 (18.0) 505 (19.9)
D51PX 505 (19.9) ⎯

D51EX/PX-22 2-35
OPERATION
BLADE ANGLE CONTROL
Rotate the knob to the right or left to angle the blade.
l (g) LEFT ANGLE:
l (h) HOLD: Blade is stopped and held in this position.
l (i) RIGHT ANGLE:
Remark
When performing only angling operation, be sure to set the
lever in the neutral (HOLD) position and rotate the knob to
the right or left.

If the angling operation is performed while the lever is not in

the neutral (HOLD) position (while either or both of lifting and
tilting operations are performed), all of those operations can
be continued, but the moving speed of the blade is lowered.
Select the operations according to the type of the work.
If the lifting or tilting operation is performed while angling
operation is performed, the machine moves similarly to the
above.

2-36 D51EX/PX-22
 OPERATION
WORK EQUIPMENT LOCK LEVER

l When leaving the operator's compartment, set the work equipment lock lever securely to the LOCK
position. If the work equipment lock lever is not at the LOCK position and the control levers are
touched by mistake, it may lead to serious personal injury.

l If the work equipment lock lever is not set securely to the LOCK position, the work equipment may
move and cause serious injury. Check that it is in the position shown in the diagram.

l When parking the machine or when carrying out maintenance, always lower the work equipment to the
ground, then set the work equipment lock lever to the LOCK position.

This lever (6) is a device to lock the work equipment control lever.
When it is set to the LOCK position, the movement of the work
equipment is locked.
The blade control lever can move even when the lever is at the LOCK
position, but the control oil pressure of the blade control is locked, so
the blade does not move.
If the blade control lever is at the FLOAT position and the safety lever is
set to the LOCK position, the blade control lever is automatically
returned to the HOLD position.
Remark
When stopping the engine, lower the blade to the ground, set
the work equipment lock lever to the LOCK position, then
stop the engine.

D51EX/PX-22 2-37
OPERATION
FUEL CONTROL DIAL

l Check to be sure steering, forward-reverse, gear shift lever is in the NEUTRAL position, when operat-
ing the fuel control dial to the full position, while the machine stands. If the steering, directional and
gear shift lever is in a forward or reverse travel position and the fuel control dial is turned to the full
position, there is a danger that the machine may suddenly move which could cause serious personal
injury.

l If the steering, directional and gear shift lever is in the forward or reverse travel position, check the
surrounding area to be sure it is safe, then turn the fuel control dial slowly to the FULL position.

This dial (1) is used to control the engine speed and output.
l (A) MAX High idle position: Turn the dial to the right.
l (B) MIN Low idle position: Turn the dial to the left.
Remark
If high-speed travel is not needed and the work consists of
comparatively light loads, return the fuel control dial slightly
from the FULL speed position towards low idle. This
improves the fuel consumption efficiency and also reduces
noise.
For finishing and leveling work or spreading gravel, return the
fuel control dial slightly from the FULL speed position towards
low idle. This reduces shoe slip and increases the service life
of the undercarriage.

2-38 D51EX/PX-22
 OPERATION
DECELERATOR PEDAL

l 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.

l When traveling on flat ground, the decelerator pedal can be used to stop the machine. However, this
does not mean that the brake is applied. On slopes, even if the decelerator pedal is depressed and the
engine speed is reduced, the machine may move, so be particularly careful.

l When climbing down a slope, select a gear speed which actuates the engine brake and press the
brake pedal, when necessary.

This pedal (4) is used to lower the engine speed and reduce the travel
speed.
Depress this pedal to reduce the speed when shifting between forward
and reverse or when stopping the machine.

BRAKE PEDAL
This pedal (3) is used for reducing travel speed without reducing engine
speed.
When the pedal is depressed, travel speed is reduced from set point to
stop until the detent is reached. Beyond the detent, the parking brake
will be applied.
When traveling on flat ground, use the decelerator pedal to stop the
machine.

D51EX/PX-22 2-39
OPERATION
PARKING BRAKE LEVER

l When parking the machine, always set the parking brake lever in the LOCK position.

l If the parking brake lever is operated, the brake is applied, even when the machine is traveling.

l The machine will suddenly stop, and this is dangerous. For this reason, do not operate the parking
brake lever when the machine is moving, except in emergencies.

This lever (7) is the control lever for the parking brake. The parking
brake is applied when the lever is set to the LOCK position.
Remark
If the parking brake lever is not at the LOCK position when
the engine is started, the limit switch is actuated and the
engine will not start.

2-40 D51EX/PX-22
 OPERATION
DOOR AND WINDOW SYSTEM

DOOR - OPEN LOCK

(Machines equipped with cab).
Use this when your want to keep the door held open.
1. Push the door against the door catch (1). The door will be held by
the door catch.

2. To release the door, pull lever (2) of the door catch towards the
front of the machine. This will release the catch.
l When keeping the door open, fix it securely to the catch.
l Always close the door when traveling or carrying out
operations.
l Leaving the door open could or may cause the door to break.
l Keep the door locked open securely. The door may swing
closed because of the vibration.

SASH GLASS INTERMEDIATE LOCK

(Machines equipped with cab)
When working with the cab sash glass open, use this lock to prevent the
glass from chattering.

l When the lever is in the FREE position, the glass can be

opened or closed.
l When the lever is moved to the LOCK position, the glass is
fixed in position.

Remark
Always close the window lock when traveling or carrying out
operations. Leaving the window lock open may cause the
window to break.

D51EX/PX-22 2-41
OPERATION
SAFETY LOCKS AND SECURITY
It is the operator or person performing maintenance on the machine who is responsible for the security of the machine and its
work equipment. Failure to safely secure the machine may result in personal injury, injury to other personnel or tampering by
unauthorized personnel. Always properly secure the machine when not in use.

IGNITION SWITCH KEY

Always remove the ignition ley when leaving the machine even for a
moment. Failure to do so may result in access to machine by
unauthorized personnel.

DOOR LOCK

l Before the releasing the door lock, always stop the

machine on flat ground.
l Never release the door lock on a slope. The door may
suddenly close and cause injury.
l When releasing the door lock, do not extend your body
or hands outside the machine and do not put your hands
on the door frame. The door may suddenly close and
cause injury.

CAP, COVER WITH LOCK

Locks are installed on the fuel tank filler, hydraulic tank filler,
operator's cab, engine hood, battery box cover, right side door of the
machine, and left side door of the machine. Use the starting key to open
and close the caps, doors and covers.
Insert the key as far as it will go, then turn it. If the key is turned before
it is inserted fully, it may break.

l There is an optional panel cover available.

2-42 D51EX/PX-22
 OPERATION
OPENING AND CLOSING CAP WITH LOCK
1. Opening the hydraulic tank cap.
A. Insert the key into the key slot.

B. Turn the key counter clockwise, align the key groove with
mark on the cap, then open the cap by turning cap clockwise.

See “RELEASING INTERNAL PRESSURE ON HYDRAULIC SYS-

TEM” on page 3-41.

2. When locking fuel cap.

A. A padlock must be used.

See “REMOVING FUEL CAP” on page 2-70.

D51EX/PX-22 2-43
OPERATION
LOCKABLE AREAS
Always lock the following places:

A. Doors of operator’s cab.

Always remember to close all windows.

B. Fuel tank filler port.

C. Hydraulic tank filler port

D. Engine hood.

E. Battery box cover.

F. Hydraulic tank cover.

G. Fuel tank cover

SEAT POCKET
There is a pocket on the back of the operator's seat.
Keep the Operation & Maintenance manual in this pocket so the
operator can read it whenever necessary.

Remark
It is important to keep this pocket locked on machines with a
canopy.

2-44 D51EX/PX-22
 OPERATION
‘

ADDITIONAL FEATURES AND ACCESSORIES

Some machines are equipped with these listed features and accessories, if your machine is equipped with the listed features or
accessories it is important to know where they are located and how to operate them in order to obtain there maximum
facilitation and comfort.

AIR CONDITIONER AND FEET HEATER

GENERAL DESCRIPTION OF CONTROL PANEL

1. Mode selector switch 3. Temperature control switch

2. Blower speed selector switch

MODE SELECTOR SWITCH

Use switch (1) to select the air conditioning mode.

l Position (a): Cooler/air conditioner system.

The air conditioning can be used, the heat cannot be used.
l Position (b): Heater.
The heater can be used, the air conditioning cannot be
used.
l Position (c): Dehumidify/ defrost.
Both heating and cooling can be used.

D51EX/PX-22 2-45
OPERATION
BLOWER SPEED SELECTOR SWITCH
Use switch (2) to select the blower speed and turn the air conditioner
ON or OFF.
The air flow can be set to four stages:
l 1 (low) Ü 2 Ü 3 Ü 4 (high)
When the switch is turned to the OFF position, the power is off and the
air conditioner is stopped.

TEMPERATURE CONTROL SWITCH

Use switch (3) to control the temperature in the cab compartment.
When the dial is turned counter-clockwise (direction C) the air tempera-
ture becomes cooler.
When the dial is turned clockwise (direction H) the air temperature
becomes warmer.

PREVENTION OF DUST ENTRY

Dust may be prevented from entering the cab of the machine by
pressurizing the cab air.
l Close all windows and doors.
l Set the air flow selector switch (2) to any position between 1 and 4.
l Set the mode selector switch (2) and temperature switch (3) to any desired position.

It is important to keep all windows and doors closed in order for this method to pressurize the cab and keep dust from entering.

2-46 D51EX/PX-22
 OPERATION
PRECAUTIONS WHEN USING AIR CONDITIONER
Listed are some general operating tips when using the air conditioner on this machine.
VENTELATION TIPS
l If you smoke while using the air conditioner, the build up of smoke inside the enclosed cab may irritate your eyes. It is
advised to open a window while smoking and using the air conditioner to avoid this problem.
l You may also want to open the window occasionally when using the air conditioner for long periods of time.

TEMPERATURE TIPS
l Be careful not to let the inside of the cab to become too hot or too cold. High heat may cause drowsiness or fatigue while
colder temperatures should be no cooler than 5 to 6oC (9 to 10oF) to avoid becoming too cold.

VENT DIRECTION
l If the outside air is warm and moist, directing the air conditioner vents toward the window glass may cause condensation
on the surface of the glass, if this happens change direction of the vent louvers or raise the temperature of the inside air
flow.

OFF SEASON AIR CONDITIONER OPERATING TIPS

l During the colder seasons when the air conditioner is not needed it is advised to occasionally operate the air conditioning
unit to circulate the refrigerant and lubricate the internal parts of the air conditioning system. Doing so will lengthen the
life of the air conditioning system.

Remark
When the outside temperature is too low and you will be operating the air conditioner, avoid running the engine
at high speeds, this may damage the refrigerant compressor. If temperatures are lower than -0.5 to 4.2oC (31
to 39oF) the air conditioner system will not operate, this is normal.

D51EX/PX-22 2-47
OPERATION
FEET HEATER
The feet heater (8) is optional on the open ROPS and standard on the
enclosed cab machines. It is located under the seat to provide floor heat
for the operator.

FEET HEATER FAN SWITCH

This switch is used as an ON/OFF switch for the feet heater system.
When the switch is used the lamp inside the switch will be illuminated.
l HIGH: Push right half of switch for high heat flow.
l LOW: Push left half of switch for low heat.
l OFF: Push the opposite side of the switch to center the switch
and turn the fan off.

SHUTTING FEET HEATER SYSTEM DOWN

(Open ROPS)
To control coolant flow to the feet heater coil:
l Remove the floor mat and floor plate to access the valve.
l The valve (A) is located under the floor on the left side of the cab.
l The temperature can be regulated by closing the valve partially.

Remark
Coolant flow is controlled by an electric valve on the cab
machines.
Coolant flow is controlled by an electric valve on the cab
machines.
For cab machine, the Temperature Control Switch (2-47) will operate an eletric valve to allow coolant flow to
the heather coil.

2-48 D51EX/PX-22
 OPERATION
RADIO
EXPLANATION OF FEATURES

1. Power switch/volume control 8. Cassette door

2. Auto-store/preset scan button 9. Fast forward, rewind buttons
3. Base control knob 10. Preset buttons
4. Treble control knob 11. Metal tape button
5. Loudness button 12. Manual tuning buttons
6. Time/radio display selector button 13. Seek buttons
7. Tape eject button 14. Band selector button
A. Band display E. Fast forward or reverse display
B. Metal tape display F. Preset display
C. Signal display G. Time/Frequency display
D. Play display

D51EX/PX-22 2-49
OPERATION

POWER SWITCH/VOLUME
Turn this knob (1) to the right until it clicks to turn the power on.
Turn this knob to the left to decrease the volume.
Turn this knob to the right to increase volume.
Turn this knob to the left until it clicks to turn the power off.

AUTO-STORE/PRESET SCAN BUTTON

Use this button (2) to actuate the preset scan and auto-store
functions.
l Auto-store
l Each time this button is pressed for more than two seconds
while in radio reception, this auto-store function
automatically starts to search for the desired station within
a receivable band, and memorize the frequency in the
preset memory. During this scanning process, the
frequency shown in the right side of display continues to
change. This indicates that each frequency is memorized
in the auto-store.
Remark
The auto-store function cannot be used when the channel display is flashing.
When the display is flashing, the preset scan function is being used.

l Preset scan
l If this button is pressed for less than 0.5 second while in radio reception, programs from the six preset stations in the
same band will be broadcast one after another for five seconds each, starting from No. 1 through No. 6 stations
consecutively.
l When the desired station is found, press the button again. This stops the preset scan tuning process and switches to
ordinary broadcasting. The same process will be repeated continuously until the button is pressed again.

BASS CONTROL KNOB

Turn this button (3) to the left to reduce the low tones; turn it to the
right to emphasize the low tones.
Direction (a): Low tone reduced direction (b): Low tone
emphasized.

2-50 D51EX/PX-22
 OPERATION
TREBLE CONTROL KNOB
Turn this button (4) to the left to reduce the high tones; turn it to the
right to emphasize the high tones.
l Direction (a): High tone reduced.
l Direction (b): High tone emphasized.

LOUDNESS BUTTON
This button (5) is used when playing at low volume. It makes it
possible to hear more easily by emphasizing the low tone when the
low tones are weak.
l Push button: Actuated ON.
l Push button again: Canceled OFF.

TIME/RADIO DISPLAY SELECTOR BUTTON

This button (6) is used to switch between the “Radio/tape display”
and the “Time display”.

CORRECTING THE TIME

l Press the button to set the time display.
l (A) Correcting hour:
l Keep the DISP button pressed and press the bottom
(H) of the TUNING button to correct the hour.
l (B) Correcting minute:
l Keep the DISP button pressed and press the top (M)
of the TUNING button to correct the minute.

D51EX/PX-22 2-51
OPERATION
TAPE EJECT BUTTON
This button (7) is used to stop the tape and to eject the cassette.
When this button is pressed, the tape is ejected and the radio plays.

CASSETTE DOOR
Set the cassette with the exposed portion of the tape on the right
side and insert it through the cassette door (8).

FAST FORWARD, REWIND BUTTONS

These buttons (9) are used to fast-forward or rewind the tape.
FAST-FORWARD/REWIND
l If you press the button pointing in the same direction as
the lighted arrow indicating the direction of play, (E) the
tape will be fast-forwarded; if you press the button
pointing in the opposite direction, the tape will rewind.
l To stop the tape, lightly press the button that is not locked.
The fast-forward or rewind operation will be cancelled.
l If the fast forward and rewind buttons are pressed at the
same time, the tape will change sides.

PRESET BUTTONS
These buttons (10) are used to call up the broadcast station
frequencies preset in memory for each of buttons No. 1 to No. 6.
It is possible to preset 18 stations (FM: 12; AM: 6) with these
buttons.

2-52 D51EX/PX-22
 OPERATION
METAL TAPE BUTTON
(Used also for preset button No. 5)
This button (11) is used when playing a metal or chrome tape. This
button is also used for preset button 5. When it is pressed, “MTL”
appears on the display (B).

MANUAL TUNING BUTTONS

These buttons (12) are used for manual tuning.
When “s” button is pressed, the frequency goes up; when “t”
button is pressed, the frequency goes down. If the button is pressed
down and held, the frequency will change continuously.

SEEK TUNING BUTTONS

These buttons (13) are used to seek tuning.
When the “SEEK UP” button is pressed, the search automatically
goes up; when the “SEEK DOWN” button is pressed, the search
automatically goes down.
When the next station that can be received is found, it automatically
stops.

BAND SELECTOR BUTTON

When this button (14) is pressed, the band is switched between
FM1, FM2, and MW (AM). The band is shown on the display (A).

D51EX/PX-22 2-53
OPERATION
METHOD OF OPERATION
METHOD OF SETTING PRESET BUTTONS
It is possible to preset 6 MW (AM) stations and 12 FM stations (FM1: 6 stations, FM2: 6 stations).
Remark
If you are playing the cassette, press the tape eject button to stop the tape.
METHOD OF AUTO PRESET
A. Use band selector button (1) to select MW (AM), FM1 or
FM2.

B. Press auto-store/preset scan button (2) for less than 0.5

seconds.

C. The preset scan tuning function automatically searches for

the desired station within the same band and can memorize
as many as six stations in the preset memory.

METHOD OF MANUAL PRESET

A. Use band selector button (1) to select MW (AM), FM1 or
FM2.

B. Press manual tuning buttons (2) or seek tuning buttons (3).

C. Press preset button (4) of the number to be preset for two

seconds while the frequency display is being shown on the
display. (The preset channel and frequency are displayed
and the presetting is completed).

D. Repeat the steps explained in Item 2 and 3 above to preset

other stations to the subsequent numbers.

E. If you want to preset a station in the other bands, follow the steps explained in Item 1 through 4 above.

Remark
Also, use Steps 2 and 3 when changing the setting of a
preset switch to another station.
When the power is disconnected, such as when the
battery is replaced, all the settings are deleted, so preset
the stations again.

2-54 D51EX/PX-22
 OPERATION
LISTENING TO RADIO
A. Turn the ignition switch ON, then turn power switch (1)
ON.

B. Use band selector button (2) to select MW (AM), FM1 or

FM2.

C. Select the station with the preset buttons (3).

Remark
In case you do not promptly remember the number
assigned to a certain preset station, press
auto-store/preset scan button (4) for less than 0.5
seconds. The preset six stations will broadcast one after
another for five seconds each. When the desired station
broadcasts, press the button again and scan tuning
stops.
D. If you want to tune into a station that is not preset, use
either seek tuning button (5) or manual tuning button (6).

E. Adjust the volume, balance, and tone as desired.

F. When turning the radio OFF, turn power switch (1) to the
left until it clicks.

Remark
To switch to the radio when listening to a cassette, press
the cassette eject button to stop the tape.
If you insert a cassette when listening to the radio, the
tape will start to play.

LISTENING TO A CASSETTE TAPE

A. Turn the ignition switch ON, then turn power switch (1)
ON.

B. Set the cassette with the exposed portion of the tape on the
right side and push it past the cassette door. The tape will
automatically start playing. If the arrow indicating the
direction of play is pointing to the right, the top side is
being played; if the arrow is pointing to the left, the
bottom side is being played. When the tape reaches the
end, it is automatically reversed and the other side starts to
play.

C. When finished with the tape, press the cassette eject button to eject the tape and automatically switch to the radio.

D51EX/PX-22 2-55
OPERATION
REVERSING TAPE
When listening to the tape, press both FAST FORWARD,
REWIND buttons (A) and (B) at the same time lightly. When this is
done, the tape direction display will be reversed.

PRECAUTION WHEN USING

l If a voltage greater than the specified voltage is input, it may cause fire, electrocution, or other failure.
Never input any voltage other than the specified voltage.

l Places inside the radio are under high voltage. Do not remove the cover.

l Do not carry out any modifications. This may cause fire, electrocution, or other failure.

l If the sound cannot be heard, nothing is displayed, or any other problem occurs, turn off the power
switch and ask your Komatsu distributor to make repairs without delay.

l Stow the antenna when traveling in places with low overhead clearance.
l To ensure safety during operations, keep the volume at a level where it is possible to hear other machines.
l If water gets inside the speaker case or radio (auto tuning), it may cause a serious problem, take care not to let water get in
these items.
l Do not wipe the scales or buttons with benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use a cloth
soaked in alcohol if the equipment is extremely dirty.

HANDLING CASSETTE TAPE

Clean the tape head approximately once a month with a commercially available head cleaning tape.
Do not leave the tape any place where it is exposed to direct sunlight, any place that is excessively dusty, or any place where
there is a magnetic field.
Do not use 120-minute tapes. The tape is thin and it easily gets caught up inside the cassette player.
If the tape is slack, it easily gets caught up inside the cassette player. Use a pencil to wind in the tape to remove any slack.
Do not use any cassette tape if the label has started to come off. It may cause defective rotation, or it may be impossible to get
the tape out of the cassette player.

2-56 D51EX/PX-22
 OPERATION
ASHTRAY
(Machines equipped with cab).
This is on the left side of the operators seat.
Always make sure that you extinguish the cigarette before you close the
lid.

LUNCH BOX HOLDER STRAP

This is the place to put your lunch box.
Hold it in position with the strap.
It can also be used for other things.

CUP HOLDER
This is a place to put cups or cans.
Do not use other locations to hold drinks, they could spill and damage
electrical components. Always use the cup holder when you have
liquid drinks.

TOOL BOX
The tool box is inside the battery compartment on the right of the
machine near the rear.

D51EX/PX-22 2-57
OPERATION
GREASE PUMP HOLDER
(optional).
The grease pump holder is in the rear side of the battery box. Be sure it
is properly held in place with the support strapping.

ELECTRICAL POWER ADAPTER

l Do not use cigarette lighter for 12V equipment.

l When using this outlet, do not exceed 120W (24V x 5A)

l Machines equipped with cab.

l It is possible to remove the cigarette lighter (12) and use this
socket as a power supply.
l Capacity of cigarette lighter: 120W (24V x 5A)
l Accessory socket (13) is used for low amp 12V equipment.
l Capacity of accessory socket: 144W (12V X 12A)
l Machines equipped with canopy only.
A. Open the tank side cover on the left side of the machine.

B. There is a connector for the power take off (1).

C. This connector is secured in place with clamps.

l Capacity (1) CN17: 120W (24V x 5A)

l Use with ignition switch in the “ON” position.

Remark
Ground the negative cable (-) to the frame. Do not ground the
wiring to the engine.
Be sure the area is clean and free of paint when grounding cable.

2-58 D51EX/PX-22
 OPERATION
BATTERY DISCONNECT SWITCH
Remark
Keep the battery disconnect switch in the ON position, EXCEPT WHEN:
l Storing the machine for one or more months;
l Repairing electrical system;
l Handling batteries;
l Replacing fuses or fusible links;

When you switch off the battery disconnect switch, wait more than one minute after shutting off the engine.
Never turn of the switch while the engine is running, otherwise, electrical system may be damaged.
When the battery gets switched off, power supply to all electrical systems is disconnected and store data for
clock time settings and radio channels may be lost.

The battery disconnect switch is used for switching on or off power

supply to the electrical system of the machine.
The switch is located behind the machine’s left front cover side-
cover.

(O) OFF position.

The flow of eletricity is shut OFF. At this position, the switch key can be pulled
out.

( I ) ON position.
The flow of eletricity is carried to electric circuits. Be sure that the switch is set in
this position before starting the machine engine.

D51EX/PX-22 2-59
OPERATION
FUSES

FUSES
Remark
Before replacing a fuses, be sure to first turn the stating switch to the OFF position, wait over one minute, then
switch off the battery disconnect switch and take out the battery disconnect switch key.

The fuses protect the electrical equipment and wiring from burning out.
If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.
FUSE CAPACITIES AND CIRCUIT NAMES

No. Fuse capacity Name of circuit

1 20 A Lamp
2 10 A Horn
3 10 A PPC lock
4 30 A A/C (optional)
5 10 A CR710 1
6 10 A Center brake
7 30 A Cab battery 1
8 30 A Cab battery 2
9 15 A Ignition switch
10 30 A CM850 1
11 20 A Power port
12 15 A Pre-heater relay
13 10 A Foot heater
14 15 A Air suspension seat (optional)
15 10 A CR710 2
16 10 A Monitor
17 5A Spare
18 10 A Service connector
19 10 A Cab continuous power source
20 5A CM850 (ACC) 2
*Cab machines (equipped with cab)
Fuse box (2) (equipped with cab)

No. Fuse capacity Name of circuit

A 10A Radio memory

B 20A Additional work lamps
C 20A Cigarette lighter (12V socket)
D 10A Radio, cab lamp
E 10A Front and rear wiper
F 10A Left and right door wipers

2-60 D51EX/PX-22
 OPERATION
CHASSIS
l Open the tank side cover on the left side. Fuse box (1) is installed
inside.

CAB (machines equipped with cab)

l Fuse box (2) is installed in the ceiling at the rear right.

D51EX/PX-22 2-61
OPERATION
PRECAUTIONS BEFORE STARTING WORK OPERATIONS
Before starting your work operations, it is important to perform several procedures to be sure your equipment is in a safe
operating condition. It is also important to be aware of the hazards involved when operating your machine.

PRE-OPERATIONAL CHECKS
Before starting your machine and preceding with any work operations, it is important to be sure your machine is safe to
operate. Below is a list of some basic items to check before any work is to begin. If any problems are found during your
Pre-operational Check, have them repaired immediately. Never operate a machine that is unsafe, damaged or in need of repair.

WALK-AROUND CHECKS
Before starting the engine, look around the machine and under the machine to check for loose nuts or bolts, or leakage of oil,
fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check for loose wiring and
accumulation of dust at places which reach high temperatures.

Remove any flammable materials from around the battery or engine muffler, or other high temperature
engine parts. Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and be sure to
repair any abnormalities, or contact your Komatsu distributor.

Always check the items in this section before starting the engine each day.
1. Check for damage, wear in work equipment, cylinders, linkage, hoses.
Check to be sure there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If any
abnormality is found, repair it.
2. Remove dirt and dust from around engine, battery and radiator
Check if there is any dirt or dust accumulated around the engine or radiator. Check also if there is any flammable material
(dead leaves, twigs, grass, etc.) accumulated around the battery or high temperature engine parts, such as the engine
muffler or turbocharger. Remove all such dirt or flammable material.
3. Check for leakage of coolant or oil around engine.
Check to be sure there is no leakage of oil from the engine or leakage of coolant from the cooling system. If any
abnormality is found, repair it.
4. Check for oil leakage from hydraulic equipment, hydraulic tank, hoses, joints.
Check to be sure there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking.
5. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from rollers.
6. Check for damage to the handrail, loose bolts. Repair any damage and tighten any loose bolts.
7. Check for damage to gauges, monitor, loose bolts
Check to be sure there is no damage to the gauges and monitor in the operator's cab. If any abnormality is found, replace
the parts. Clean off any dirt on the surface.
8. Clean rear view mirror, check for damage
Check to be sure there is no damage to the rear view mirror. If it is damaged, replace it with a new mirror. Clean the
surface of the mirror and adjust the angle so the view to the rear can be seen from the operator’s seat.
9. Seat belt and mounting clamps. Check to be sure there is no abnormality in the seat belt or mounting clamps. If there is
any damage, replace with new parts.
10. Check draw bar and hooks. If damage is found, contact your Komatsu distributor for repair.

2-62 D51EX/PX-22
 OPERATION
CHECKS BEFORE STARTING
Always check the items in this section before starting the engine.
CHECK COOLANT LEVEL, ADD COOLANT

Do not open the radiator cap unless necessary. When checking the coolant, wait for the engine to cool
down and check the sub tank.
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high
internal pressure. If the cap is removed to drain the coolant in this condition, there is a danger of burns.
Wait for the temperature to go down, then turn the cap slowly to release the pressure before removing it.

1. Open the tank side cover on the left side of the machine, and check
the coolant in sub-tank (1) (shown in the diagram on the right).

2. It should be between the FULL and LOW marks. If the coolant

level is low, add coolant to the FULL level through the filler port of
sub-tank (1).If the sub tank is empty, there is probably leakage of
coolant. After inspecting, repair any abnormality immediately. If
there is no abnormality, check the coolant level in the radiator.

D51EX/PX-22 2-63
OPERATION
DRAINING THE PRE-FILTER
1. Set a container under the pre-filter cartridge to catch the fuel (Do
not drain Diesel fuel onto the ground).
2. Be sure the fuel supply valve is in the CLOSED position as shown
on the right.
3. Loosen drain valve (4) and drain all water and sediment in the
transparent cap (2) and also all fuel accumulated in filter cartridge
(1).
4. Be sure nothing more comes out from drain hose, then close drain
valve (4).

Do not operate the work equipment with the engine service

doors in the open position, damage to the service doors or
hood may result.

5. (Service only at filter change) Coat O-ring portion (7) with a suit-
able amount of grease. When doing this, be careful not to let the
grease get stuck to the drain valve water drain port (8) or drain
valve thread (9).
6. Tighten drain valve (4) by hand until it contacts the bottom of the
transparent cap (2).
7. Remove the fuel container.

2-64 D51EX/PX-22
 OPERATION
CHECKING AND ADDING OIL TO HYDRAULIC TANK

The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Wait for the temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

1. Set the work equipment in the posture shown in the diagram on the
right, then check the oil level and add oil if necessary.
2. If the work equipment is not in the condition shown in the
diagram on the right, start the engine, run the engine at low speed,
lower all work equipment and attachments.

3. On the left rear side of the machine, open the door and locate the
sight gauge (G) on the tank.

4. Check sight gauge (G). The oil level should be between the H and
L marks.
5. If the level is below the L mark, add oil through oil filler (F) at the
top of the hydraulic tank.

Remark
The oil level will vary depending upon the oil temperature.
Accordingly, use the following as a guide:
Before starting operation: Between H and L levels.

Oil temperature 10 to 30oC (50 to 86oF).

Normal operation: Around H level.

Oil temperature 50 to 80oC (122 to 176oF).

H Do not add oil above the H line. This will damage the hydraulic circuit or cause the oil to spurt out.

D51EX/PX-22 2-65
OPERATION
OPENING HYDRAULIC TANK CAP
1. Stop the machine on firm level ground.
2. Lower the blade to the ground, then stop the engine.
3. To release the internal pressure, Turn ignition switch to the ON position. Move the work equipment lock lever to the
UNLOCKED position. Move the work equipment to the FLOAT position.

Remark
The accumulator no longer provides pilot pressure once the work equipment lever returns to the NEUTRAL
position after about one minute.
4. Insert ignition key into cap lock.
5. Turn key fully counter-clockwise to unlock cap.

6. Push down on cap and rotate cap counter-clockwise at the same

time.

When removing cap always be aware there may be pressure

in the hydraulic tank. Wear eye protection when opening
hydraulic tank.

7. Once cap is loose, lift cap off to access hydraulic tank filler neck.
8. To install, align cap lock tabs with filler neck groves and install cap
by turning cap back, clockwise.
9. Lock cap with key.

2-66 D51EX/PX-22
 OPERATION
CHECK AND DRAIN WATER SEPARATOR
1. Set a container under the pre-filter cartridge to catch the fuel (Do
not drain Diesel fuel onto the ground).
2. Be sure the fuel supply valve is in the CLOSED position as shown
on the right.
3. Loosen drain valve (4) and drain all water and sediment in the
transparent cap (2) and also all fuel accumulated in filter cartridge
(1).

Do not operate the work equipment with the engine service

doors in the open position, damage to the service doors or
hood may result.

4. Be sure nothing more comes out from drain hose, then close drain
valve (4).
5. Tighten drain valve (4) by hand until it contacts the bottom of the
transparent cap (2).
6. Remove the fuel container.
l On this machine a sensor is located on the transparent cap (2)
The water separator caution lamp is located on machine
monitor.
l If water separator lamp flashes, it is an indication that water
has accumulated in the filter.
l In this case, drain filter immediately.
If water accumulated in transparent cap (2) freezes, the water separator
caution lamp may not flash. In addition, after the engine is started, the
rise in temperature around fuel pre-filter (1) will melt the frozen fluid in
the water separator. This will cause the lamp to flash.
It is advised when operating the machine in colder climates to drain the
water separator frequently in order to avoid this problem.

7. (Service only at filter change) Coat O-ring portion (7) with a suit-
able amount of grease. When doing this, be careful not to let the
grease get stuck to the drain valve water drain port (8) or drain
valve thread (9).
8. Tighten drain valve (4) by hand until it contacts the bottom of the
transparent cap (2).
9. Remove the fuel container.

Remark
If transparent cap (2) becomes dirty or cloudy, clean or replace cap when replacing pre-filter.
When drain valve (4) has been removed during the cleaning operation, coat the O-ring with grease and tighten
until it contacts the bottom. Do not overtighten drain valve, damage to O-ring may result.
If drain valve is too tight or hard to get to, access it through the engine front grill.

D51EX/PX-22 2-67
OPERATION
-

CHECKING AND ADDING ENGINE OIL

Parts and oil are at high temperature immediately after the engine is stopped and may cause serious
burns. Wait for the oil temperature to go down before checking oil.

1. Open the engine side cover (1) on the left side of the machine.

Do not operate the work equipment with the engine service

doors in the open position, damage to the service doors or
hood may result.

2. Remove dipstick (G), and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into tube, then remove it.

4. The oil level should be between the (H) and (L) marks on dipstick
(G).
If the oil level is below the (L) mark. Remove oil fill cap and add
oil through oil filler (F).
5. If the oil is above the (H) mark on the gauge, find a suitable
container to drain the oil into.

2-68 D51EX/PX-22
 OPERATION
6. Remove cover (1), at the bottom front of the machine and pull drain
hose out to drain the excess oil by opening drain valve (a). Once
ample amount of oil is drained, close valve (a) and check oil level.
l The oil drain and coolant drain are located in behind front grill.
7. If oil level is correct, return drain hose, tighten oil drain valve (a)
and install cover.
Remark
When checking the oil level after the engine has been
operated, wait for at least 15 minutes after stopping the
engine before checking. If the machine is at an angle, make it
horizontal before checking.

Do not operate the work equipment with the front grill in the
open position, damage to the front grill or hood may result.

CHECK ELECTRICAL WIRING

If fuses are frequently blown or if there are traces of short-circuting in the electrical wiring, contact your
Komatsu distributor to locate the cause and make the repair. Keep the top surface of the battery clean and
check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the
vent hole.

Check for loosened terminals. If found, tighten them. Pay particular attention to the electric wiring when checking the battery,
engine starting motor and alternator. Be sure to check to be sure there is no flammable material accumulated around the
battery. If any is found, remove immediately.
CHECK OR ADD FUEL

When adding fuel, never spill the fuel or let it overflow. If any
fuel has spilled, wipe it up immediately. If fuel has spilled
over soil or sand, remove that soil or sand. Fuel is highly
flammable and dangerous. Never bring flames near fuel.

1. Turn the engine ignition switch to the ON position and check the
fuel level gauge (G) on the monitor panel for fuel level.

D51EX/PX-22 2-69
OPERATION
After checking, turn the switch back to the OFF position.
2. If fuel is found to be low, remove fuel filler cap (F) on the fuel tank
and add fuel through the filler port.

REMOVING FUEL CAP

1. Open tab (H) and insert ignition key.
l To open cap, turn key clockwise.
l To lock cap, turn key counter-clockwise.

2. To open cap, rotate cap counter clockwise.

3. Lift cap off the fuel tank fill neck.

Remark
Inspect the primary fuel strainer in fuel tank neck, if blocked,
remove and clean the strainer. Do not discard the primary
fuel strainer.
Occasionally check the vent ports in the fuel cap for any
blockage. If blocked clean the vent ports out.

2-70 D51EX/PX-22
 OPERATION
CAP VENT
Occasionally the fuel cap vents (1) may be come clogged over time. If
the cap vent should become clogged this may restrict the fuel flow from
the fuel tank to the engine.
Remove the fuel cap and clean the vents (1) out using an approved
nonflammable cleaning solvent.

When carrying out work on slopes, check carefully to be

sure the fuel level is high enough to prevent air from being
sucked into the engine when the machine is at an angle.

FUEL TANK STRAINER

The fuel tank strainer (2) is located in the fuel fill neck of the fuel tank.
If the fuel strainer should become clogged, remove the strainer and
clean it in an approved nonflammable cleaning solvent then reinstall it
into the fuel tank neck.
Remark
Do not discard the fuel strainer if it should become blocked.
Filling the fuel tank without this strainer in place may allow
debris to enter the fuel system.
Always be careful when inserting a fuel fill nozzle into the fuel
tank neck as not to damage the fuel strainer.

CHECK WORK LAMPS

Check to be sure the working lamps and lamps inside the instruments
light up properly. Check to be sure there is no dirt or damage.
If any lamp does not light up, the bulb is probably blown up or there is a
disconnection, so ask your Komatsu distributor to carry out repairs.
1. Turn the ignition switch to the ON position.

2. Set the lamp switch to the F or FR position and check to be sure all
the working lamp lights up.

D51EX/PX-22 2-71
OPERATION
CHECK FUNCTION OF HORN
1. Turn the ignition switch to the ON position.

2. Confirm that the horn sounds immediately when the horn button is
pressed.
3. If the horn does not sound, contact your Komatsu distributor for
repair.

CHECKING THE MONITOR

1. Turn the ignition switch to the “ON” position.

2. Check to be sure all the monitors lights and gauges light for
approximately two seconds. For details. See “CHECK MONITOR
SYSTEM” on page 2-7.

Remark
If the lamps do not light up, there may be a failure or open in
the circuit. Contact your Komatsu distributor.

2-72 D51EX/PX-22
 OPERATION
CHECK OPERATION OF BACKUP ALARM
Check to be sure the backup alarm works when the machine is placed in
reverse. If not, contact your Komatsu distributor.
1. Turn the ignition switch to the “ON” position.

2. Be sure the parking brake lever (7) is in the LOCK position.

3. Move the steering lever to the REVERSE position. The alarm must
sound immediately.
4. Move the lever to the NEUTRAL or FORWARD position. The
alarm must stop operating.

D51EX/PX-22 2-73
OPERATION
AIR SUSPENSION SEAT

When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK
position to prevent any accidental contact with the control levers.

l Always adjust the operator's seat before starting each operation or when the operators change shift.
l When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully
depressed.

Remark
There is danger of damage to the air compressor, so do not keep lever (3) operated continuously for more than
1 minute.
Adjustments (C), (D), and (I) use the air compressor built into the seat, so turn the engine starting switch to the ON position
when carrying out the adjustment.
• (A) Fore-and-aft adjustment.
Pull lever (1), set the seat to a position where it is easy to
operate, then release the lever.
Fore-aft adjustment: 170 mm (6.7 in) (17 stages).
• (B) Adjusting seat angle.
Move lever (2) up, move the seat cushion at the front up or
down to set to the desired position, then release the lever.
Amount of adjustment
Forward tilt: 3 degrees
Rear tilt: 11 degrees
• (C) Setting seat for operator's weight
To protect the operator, it is necessary to adjust the suspension
to match the weight of the operator.
Pull lever (3) up fully (pull it until a click can be felt). When
the lever is released, the weight adjustment is carried out
automatically. To ensure that the weight adjustment is carried
out correctly, the operator should sit in the normal operating
position when operating the lever. If the operator raises his
body from the seat or changes the amount of weight applied to
the seat during adjustment, the air in the suspension may be
discharged.
If lever (3) is pulled lightly, the weight adjustment starts, but always pull the lever up fully (pull it until a click is felt)
before releasing it.
When operators change shifts, first release the air, then carry out the above operation.
If the operator raises his body from the seat or changes the amount of weight applied to the seat during adjustment,
the air in the suspension may be discharged.
Amount of adjustment: 80 mm (3.2 in).
After the automatic weight adjustment is carried out, the seat height is at the lowest point in the adjustment range.
Adjust the seat to the appropriate height.
• (D) Seat height adjustment
The seat height adjustment uses an air system, and it can be adjusted by each step
When adjusting the height, pull lever (3) up fully or push it down fully (when pulling it up, pull it until a click is felt).
When the seat is set at the desired height, release the lever. If the lever is kept pulled up, the position where the seat
does not rise any further is the maximum height. When the seat reaches the maximum height, the suspension
automatically goes down slightly to secure the amount of movement of the lever.
To prevent the suspension from reaching the bottom, do not set to the seat height below the adjustment range.

2-74 D51EX/PX-22
 OPERATION
• (E) Fore-and-aft adjustment of seat cushion
Operate lever (4) up, set the seat cushion to the desired position, then release the lever.
Fore-and-aft adjustment: 60 mm (2.4 in).
• (F) Adjusting reclining angle.
Move lever (5) up and move the backrest to the front or rear.
Push your back against the backrest when carrying out this adjustment. If your back is not pressing against the back-
rest, the backrest may suddenly spring forward.
Amount of adjustment.
Forward tilt: 20 degrees (over 20 degrees is free).
Rear tilt: 60 degrees.

Remark
The seat can be reclined more when the seat is pushed to the front. The amount of reclining decreases as the
seat is pushed back, so when moving the seat back, return the seat back to the upright position. If the seat
back is reclined too far, the seat back may hit the rear glass, so use it in a position where it does not contact the
glass.

• (G) Adjusting headrest angle.

Rotate the backrest to the front or rear and set to the desired angle.
Amount of adjustment: 38 degree.
• (H) Adjusting headrest height.
Move the headrest up or down and set to the desired height.
Amount of adjustment: 100 mm (3.9 in).
• (I) Lumbar support.
Operate switch (6) to give a suitable tension to the lumbar region.
When + is pressed: Tension becomes stronger.
When - is pressed: Tension becomes weaker.
Adjust the backrest to the desired curve.

D51EX/PX-22 2-75
OPERATION
ADJUST ARMREST
The height of the armrests on both sides can be adjusted at their heights.
After adjusting the operator's seat, adjust the armrests to a suitable
height.
1. Loosen bolts (1) on both sides of the operator's seat.
2. Adjust the armrests on both sides of the operator's seat to a suitable
height.
3. Tighten bolts (1) securely.

FASTENING AND REMOVING SEAT BELT

Always install a seat belt on machines equipped with ROPS.

l Before fitting the seat belt, check to be sure there is no problem in the mounting bracket and tethering
belt of the belt. If the belt is worn or damaged, replace it.

l Replace the seat belt every three years, even if the outside is free from problem.
The year of manufacture is woven on the back side of the belt.

l Always fasten the seat belt before starting operations.

l Always use the seat belt during operations.

l Do not twist the left or right side of the seat belt when fastening it.

l Check to be sure bolts of the clamp securing the belt to the chassis are not loose. Tighten them if they are loose.
l The tightening torque for the mounting bolt is: 24.5 ± 4.9 Nm (18.1 ± 3.6 lb/ft).
l If the belt surface is scratched or frayed or if the fittings are broken or deformed, replace the seat belt unit.

FASTENING AND REMOVING SEAT BELT

1. Sit on the seat, depress the brake pedal fully, and adjust the seat so
that your back is pressed against the backrest.
2. After adjusting the seat position, adjust tether belt (1). Tense the
tether belt and install it when there is no one sitting on the seat.
3. Sit on the seat and hold tongue (4) connected to wind-in
mechanism (2) and pull out the belt slowly so the belt will cover
your abdomen sufficiently.
4. Insert tongue (4) in buckle (3) until it clicks. The belt is pulled back
into wind-in mechanism (2) until it is fitted to your
abdomen. The belt is locked under this condition and cannot be
extended anymore. Fit the belt to your abdomen without twisting it.
Remark
If the belt is locked before the tongue is inserted in the
buckle, let it return to the wind-in mechanism, then repeat the above procedure from the start.
5. Pull the belt to check that it is securely locked in position.
6. When removing the belt, press the red button on buckle (3).
The belt will automatically retract.

2-76 D51EX/PX-22
 OPERATION
ADJUSTING MIRROR
Adjust the position so the mirror (1) gives a good view from the
operator's seat. In particular, be careful to adjust so that it is possible to
see people on the left and right sides at the rear of the machine.

SYSTEM “ON” CHECKS

Do not start the engine during SYSTEM “ON” CHECKS.

When starting the engine, check to be sure parking brake lock lever is securely at the LOCK position.
If the parking brake lock lever is not locked securely and the control levers or control pedal are touched
when the engine is started, the machine may move unexpectedly, and this may lead to serious personal
injury.

1. Check that parking brake lever (7) is in the LOCK position.

Remark
If this parking brake lever is not in the LOCK position, the
engine will not start.
2. Check to be sure the travel lever is in the N (neutral) position.

Remark
The engine cannot be started if the travel lever is not in the N
(neutral) position.
If travel lever (2) is in FORWARD or REVERSE, the letter P
on display panel A will flash.

D51EX/PX-22 2-77
OPERATION
3. Check to be sure blade control lever (3) is HOLD position.

4. Check to be sure work equipment lock lever (6) is locked.

2-78 D51EX/PX-22
 OPERATION
STARTING THE ENGINE
NORMAL OR COLD START PROCEDURES

l Start the engine only after sitting down in the operator's seat.
l 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.
l Check to be sure there are no persons or obstacles in the surrounding area, then sound the horn and
start the engine.
l Never use starting aid fluids as they may cause explosions.
l Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure
good ventilation.

STARTING TIPS
l Do not continue to crank the starter motor continuously for more than 60 seconds under any circumstances. If the
engine does not start, wait for at least two minutes, then repeat the procedure from Step 2 and try again.
l Before starting the engine, check the fuel control dial to be sure it is in the low idle MIN position.
l This machine is equipped with an automatic warm-up system that warms up the engine coolant quickly along with a
turbo protection function to protect the turbo charger. For this reason in cold weather, even if the fuel dial is operated
immediately after the engine starts, the engine speed may not change.
l If the fuel dial is at full speed MAX position, the engine speed may suddenly rise and cause damage to parts of the
engine. Set the fuel control to a mid-range position or low speed position.

1. Before starting the engine, check that fuel dial is at the low MIN
idling position.
2. Turn the fuel dial up slightly from the MIN position.

3. Insert the key into ignition switch and turn the key to the START
position. The engine will start.

D51EX/PX-22 2-79
OPERATION
4. When the engine starts, release the key in ignition switch.
5. The key will return automatically to the ON position.
6. Continue to run the engine at idling for 15 seconds after starting.
7. During this time, do not operate the control levers or fuel dial.

COLD WEATHER STARTS

When starting in low temperatures, do as follows:
l Do not continue to crank the starter motor continuously for more
than 60 seconds under any circumstances. If the engine does not
start, wait for at least two minutes, then repeat the procedure from
Step 2 and try again.
l Before starting the engine, check the fuel control dial to be sure it is
in the low idle MIN position.
l This machine is equipped with an automatic warm-up system that warms up the engine coolant quickly along with a turbo
protection function to protect the turbo charger. For this reason in cold weather, even if the fuel dial is operated
immediately after the engine starts, the engine speed may not change.
l If the fuel dial is at full speed MAX position, the engine speed may suddenly rise and cause damage to parts of the engine.
Set the fuel control to a mid-range position or low speed position.
l Set the fan rotation selector switch to the NORMAL ROTATION position when starting the engine or carrying out engine
warm-up operations in cold weather.

1. Before starting the engine, check that fuel dial is at the low MIN
idling position.
2. Turn the fuel dial slightly above the MIN position to the center
position.

3. Insert the key into ignition switch and turn it to the ON

position. Engine pre-heating pilot lamp will light up and eventually
go out automatically indicating preheat function is complete.

2-80 D51EX/PX-22
 OPERATION
4. You can also use the HEAT position for the specified pre-heating
time.

H The pre-heating times are as shown below.

Coolant Lighted
temperature time (sec.)
-4 to -15oC
5 to 30
(24 to 5oF)
-15oC or below
30
(5oF or below)

l If the pre-heating time is too long or too short, the engine will
not start easily. Observe the correct pre-heating time.
5. When the pre-heating is completed, turn the key in ignition switch
to the START position to start the engine.

6. When the engine starts, release the key in ignition switch.

7. The key will return automatically to the ON position.

Remark
Immediately after an engine start-up, keep the engine idling,
and while the engine is idling keep your foot off the
decelerator pedal and do not operate the work equipment.

D51EX/PX-22 2-81
OPERATION
8. When the engine stabilizes, return the fuel dial to the MIN
position to continue warm-up procedures.

PREHEAT FUNCTION
l Regardless of the ambient air temperature, if the ignition key switch
is turned from OFF position to left, preheating pilot lamp will light
up and preheating will start. (Preheating continues while the
ignition switch is held to the left.) For details on preheating see step
4.
l While preheating is being carried out, the preheating pilot lamp
lights up to show that preheating is being carried out.
l If the engine does not start using the above information, wait for
about 2 minutes and repeat the preheating procedures.
l Even if the fuel dial is operated within the time given below, the engine speed will not change.

TURBO PROTECTION FUNCTION

The turbo protection function is a function to protect the turbocharger by keeping the engine speed below 1000 rpm
immediately after the engine has been started.
l When the turbo protection function is actuated, the engine speed is held at less than 1000 rpm, regardless of the position of
the fuel dial.
l When turbo function is cancelled, the engine speed is set to the position of the fuel control dial.
l The relationship between the length of time of actuating the turbo protection function and the temperature of the engine
coolant is shown in the table.
l During operation of the turbo protection function, the machine does not accept any operation to move the machine.

Coolant temperature Turbo protection time (sec.)

Above 10oC (50oF) 0

10 to -30oC (50 to -22oF) Change 0 to 20

AUTO WARM-UP FUNCTION

This is a function to warm up the engine coolant more quickly by
raising an engine idle speed. When the auto warm-up function and the
turbo protection function are activated at the same time, the former
takes priority over the latter.
l During the warm-up operation, even if the fuel dial is set to a
position below 1200 rpm, the engine speed is held at 1200 rpm.
l This function continues to work for a maximum of ten minutes, or
until the engine coolant reaches 30oC (86oF).
l If the decelerator pedal is pressed during the automatic warm-up
operation, the automatic warm-up function is canceled and the
engine speed drops below 1200 rpm.
In addition, the automatic warm-up function is also cancelled by the
following procedure.

2-82 D51EX/PX-22
 OPERATION
1. Turn the fuel control dial to the full speed MAX position and hold it
for three seconds.
2. When fuel control dial is returned to the low idle MIN
position, the engine rpm will drop.

D51EX/PX-22 2-83
OPERATION
OPERATIONS AND CHECKS AFTER STARTING ENGINE

Emergency stop
l If there has been any abnormal actuation or trouble, turn the ignition switch key to the OFF position.

l Do not carry out operations or operate the levers or pedals suddenly while the hydraulic oil is at low
temperature. Always carry out the warming-up operation for the hydraulic equipment until the
hydraulic oil temperature monitor is displayed green.

l If the warming-up operation for the hydraulic equipment is not carried out thoroughly, and the
machine is moved, the reaction of the control levers and pedals will be slow and the movement may
not be what the operator intended. Always warm up the hydraulic equipment. In particular, in cold
areas, always warm up the hydraulic equipment thoroughly.

If any problems occur, turn the ignition switch to the “OFF” position.
If the work equipment is operated without warming up the machine sufficiently, the response of the work equipment to the
movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always perform
the warm-up operation. Particularly in cold areas, be sure to perform the warm-up operation fully.

BREAKING IN THE MACHINE

Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under
severe conditions at the beginning can adversely affect the performance and shorten the machine life.
l Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
l During break-in operations, follow the precautions described in this manual.
l Idle the engine for five minutes after starting it up.
l Avoid operation with heavy loads or at high speeds.
l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency.

WARMING UP ENGINE
l Keep an eye on coolant temperature gauge (1) while you warm the
machine up.
l Do not accelerate the engine suddenly until the warming-up
operation has been completed.
l Do not run the engine at low idling or high idling under no load for
more than 20 minutes. This will have an adverse effect on the
environment, and will also have an adverse effect on the internal
structure of the engine. If it is necessary to run the engine at idling
for more than 20 minutes, apply a load from time to time or run at a
mid-range speed.

2-84 D51EX/PX-22
 OPERATION
1. Turn fuel control dial to a point midway between low idling (MIN)
and full speed (MAX), run the engine at a mid-range speed, and run
under no load until engine coolant temperature warms up for five
minutes.

2. After warm-up is completed, check gauges and caution lamps for

proper operation. If any problem is found, repair it. Continue to run
the engine under a light load until engine coolant temperature
gauge indicator is within the green range (B).
l (A): White range
l (B): Green range
l (C): Red range
l Check for abnormal exhaust gas color, noise, or vibration. If any
problem is found, contact your Komatsu distributor.

STARTING IN COLD WEATHER

(Ambient temperature below 10°C (50°F))
After starting the engine, do not immediately start operations. First, perform the following operations and checks.
l Avoid abrupt acceleration until warm-up run is completed.
l Do not run the engine at low idle or high idle for more than 20 minutes.
l If it is necessary to run the engine at idle, apply a load or run at a medium speed from time to time.

1. Turn fuel control dial to a point midway between low idling (MIN)
and full speed (MAX).

Remark
Warm up operation is for ten minutes. When the hydraulic oil
is at a low temperature, do not carry out operations or move
the levers suddenly. Always carry out the warm-up operation.
This will help to extend the machine life. Do not suddenly
accelerate the engine before the warm-up operation is
completed.
Do not run the engine at low idle or high idle continuously for
more than 20 minutes. This will cause leakage of oil from the turbocharger oil supply piping.
If it is necessary to run the engine at idle, apply a load from time to time or run the engine at a mid-range
speed.

D51EX/PX-22 2-85
OPERATION
2. After this, operate the blade control lever fully to the RAISE
position, hold the lever in position, and relieve the left and right tilt
intermittently. Next, move the lever to the LOWER position and
lower the blade to the ground, then move the lever to the full
FLOAT position, hold the lever in position, and relieve the left and
right tilt intermittently for five minutes.

Do not operate the work equipment with the engine service

doors in the open position, damage to the service doors or
hood may result.

3. After warm-up run is completed, check gauges and caution lamps

for proper operation. If any problem is found, repair it.
l Continue to run the engine at light load until engine coolant
temperature gauge indicator and HST oil temperature gauge fall
within the green range (B).
l (A): White range.
l (B): Green range.
l (C): Red range.

Remark
If the hydraulic oil temperature is low, the machine may
deviate slightly when stopping or starting. Be particularly
careful if the machine has to be operated when the hydraulic
oil temperature gauge is still in white range (A).
4. Check for abnormal exhaust gas color, noise, or vibration. If any
problem is found, contact your Komatsu distributor.
5. After carrying out the warming-up operation, to make the
temperature of all equipment the same, run the engine at a
mid-range speed and travel slowly forward and in reverse.

2-86 D51EX/PX-22
 OPERATION
STOPPING THE ENGINE
l If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not
abruptly stop the engine except in an emergency.
l In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually,
then stop it.
1. Turn the fuel dial to (MIN) position and run the engine at low idling
speed for about five minutes to allow it to gradually cool down.
2. Lower all work equipment to the ground.

Remark
After work operations always allow the engine to cool down
for at least five minutes in the idle (MIN) position. Failure to
do so may result in damage to the turbocharger.

3. Turn the key in ignition switch to the OFF position and stop the
engine.
4. Remove the key from ignition switch.

Remark
When the key in ignition switch is turned to the OFF
position, the engine stops, but the machine power supply is
not cut immediately.
The power supply is maintained for several seconds to
enable the controller to save the operating condition to
memory and shuts down the system after that. The length of
time that the power supply is maintained depends on the
operating condition.

D51EX/PX-22 2-87
OPERATION
MOVING, STEERING, STOPPING AND PARKING THE MACHINE
Before traveling or moving the machine, it is important to know all the control functions and relevant safety regulations
for the area you will be traveling or moving the machine in. If you will be traveling on state or local roadways, be sure the
surface will support your machine and there will be no damage to the road surface from the machine. Travel at a safe
controllable speed.

PREPARATIONS FOR MOVING THE MACHINE

l When moving machine, check to be sure the area around the machine is safe, and sound the horn
before moving.

l Clear all personnel from the machine and the area.

l Use extreme care when reversing the machine. Note there is an blind spot behind the machine.

l When starting on slopes, always keep brake pedal (2) depressed, even after releasing parking brake
lever (1).

l When starting the machine off on an uphill slope, turn fuel control dial (3) fully to run the engine at full
speed. Keep brake pedal (2) to pressed, set the speed range to 1st, then operate travel lever (4) in the
direction of travel. Release brake pedal (2) slowly, and after the machine starts to move (or the shoes
start to slip), release brake pedal (2) completely.

l On flat ground, when deceleration pedal (5) is depressed, or when fuel control lever (3) is at the low
idling position, the machine is stopped, but this does not mean that the brake is applied. Be
particularly careful on slopes. Even when the engine is running at low idling, the machine may move.

1. Location of travel controls as listed above in WARNING.

2. Brake pedal 4. Travel lever 6. Speed indicator

3. Fuel dial 5. Decelerator pedal 8. Work equipment

2-88 D51EX/PX-22
 OPERATION
MOVING MACHINE FORWARD OR REVERSE
1. Move travel lever (4) to the FORWARD or REVERSE position to
move the machine off.

l Check to be sure backup alarm sounds when travel lever is

placed in REVERSE. If the alarm does not sound, contact your
Komatsu distributor.
l When the travel lever is placed in FORWARD or REVERSE,
the machine may deviate slightly to the left or right, but this is
caused by the actuation of the straight-travel compensation
mechanism and does not indicate any problem.
2. Set the work equipment lock lever (6) to the FREE position.
3. Put the blade control lever (8) in the RAISE position to raise the
blade to safe traveling height to avoid hitting any objects. Do not
raise the blade so high that it blocks your view.

4. Depress decelerator pedal (5).

5. Move travel lever (4) to the FORWARD or REVERSE position to

move the machine off.

Remark
Check the back-up alarm to be sure it is working when the
steering lever is placed in REVERSE.
When the travel lever is placed in forward or reverse the
machine may deviate slightly to the left or right, this is normal.

D51EX/PX-22 2-89
OPERATION
6. Turn the fuel control dial towards full speed (MAX) position to
increase the engine speed.

7. Release the decelerator pedal (5) slowly to move the machine off.

2-90 D51EX/PX-22
 OPERATION
CHANGING SPEED RANGES
The machine does not have to be stopped to shift gears.
Press the shift switch on the knob travel lever (4) and select the desired speed range.
SHIFTING GEARS
Press the shift switch on the travel lever to carry out the gear shifting
operation.
l Press the UP switch to shift up.
l Press the DOWN switch to shift down.
When the ignition switch is turned to the ON position, the speed range is
set by default to 1st.
For details of the method of selecting the shift mode, monitor display,
and set travel speed. See “DISPLAY PANEL (B)” on page 2-23.
If the operating load increases, the travel speed will slowly decrease and
the transmission will shift down. When the load becomes lighter again,
the transmission will shift up to the set travel speed.
When the transmission automatically shifts down, the speed range display does not change.

SHIFTING BETWEEN FORWARD AND REVERSE

The direction of travel can be changed without stopping the

machine. But to ensure safety and riding comfort, and to
extend the service life of the power train, do not keep the
machine running at full throttle when changing direction.
Depress decelerator pedal (1) and reduce the engine speed
before changing direction.

1. Depress decelerator pedal (5) to reduce the engine speed.

D51EX/PX-22 2-91
OPERATION
2. Shift travel lever (4) to the desired position.

Remark
Check to be sure the backup alarm sounds when travel lever
is placed in REVERSE. If the alarm does not sound, contact
your Komatsu distributor.
When the travel lever is placed in FORWARD or REVERSE,
the machine may deviate slightly to the left or right, but this is
caused by the actuation of the straight-travel compensation
mechanism and does not indicate any problem.

3. Release decelerator pedal (5) and raise the engine speed.

2-92 D51EX/PX-22
 OPERATION
STEERING THE MACHINE

l Avoid turning the machine on a slope. The machine will tend to slip sideways. Particular care should
be taken on soft or clay soil.

l Never make a pivot turn at high speed.

NORMAL TURN
To turn the machine while traveling, move the travel lever (1) in the
direction of the turn.

MAKING A LEFT OR RIGHT TURN

If the travel lever (1) is operated to the FORWARD position and moved
partially to the left (L) or right (R), the machine will start to turn
gradually. If the lever is moved to the left (L) or right (R), a tighter
turning radius is achieved. A gradual turn is accomplished until the
lever left (L) or right (R) motion reaches a heavy point.
Remark
Do the same when traveling in reverse.

D51EX/PX-22 2-93
OPERATION
MAKING A PIVOT TURN
To perform a pivot turn, move the travel lever in the direction of the
intended turn. As the lever is moved, a gradual turn is performed until
the lever reaches a heavy point. At the heavy point, a pivot turn is car-
ried out.

TURNING WHILE DESCENDING A SLOPE

This machine does not cross-steer even when it descends a steep slope
where it is driven down by its own weight or when it is pushed down by
a towed machine on a slope.
Remark
Cross steering means the phenomenon that the machine
turns in the opposite direction to the actual steering direction.

Remark
When carrying out a counter rotation turn the travel lever (1)
to the opposite direction in the same way.

COUNTER-ROTATION TURN
When steering the machine, if the lever is operated further from the
heavy point, the left and right tracks will rotate in opposite directions
and the machine will carry out a counter rotation turn.

2-94 D51EX/PX-22
 OPERATION
STOPPING THE MACHINE

Avoid stopping suddenly. Give yourself ample room when

stopping.

1. Depress decelerator pedal (1) and return travel lever (2) to the N
(neutral) position.
The machine will stop. If necessary use brake pedal (3) to stop and
hold the machine.

Remark
If it is difficult to stop the machine on a downhill slope using
only the decelerator pedal, use brake pedal (3) in addition to
the decelerator pedal.
If it is necessary to stop the machine suddenly, depress the
brake pedal.

1. Turn the fuel dial to (MIN) position and run the engine at low idling
speed for about five minutes to allow it to gradually cool down.
2. Lower all work equipment to the ground.

D51EX/PX-22 2-95
OPERATION
3. Turn the key in ignition switch to the OFF position and stop the
engine.
4. Remove the key from ignition switch.

Remark
When the key in ignition switch is turned to the OFF
position, the engine stops, but the machine power supply is
not cut immediately.
The power supply is maintained for several seconds to
enable the controller to save the operating condition to
memory and shuts down the system after that. The length of
time that the power supply is maintained depends on the
operating condition.
Remark
After work operations always allow the engine to cool down for at least five minutes in the idle (MIN) position. Fail-
ure to do so may result in damage to the turbocharger.

2-96 D51EX/PX-22
 OPERATION

PARKING MACHINE

l When parking the machine, select flat hard ground.

l Avoid parking the machine on a slope.

l On slopes, even if steering, forward-reverse, gear shift lever is set to the N position, the machine may
move slowly down the slope.

l If it is unavoidably necessary to park the machine on a slope, place the parking brake lever at the
LOCK position and insert blocks under the track shoes. As an additional safety measure, lower the
work equipment and thrust the blade into the ground.

l If the work equipment control lever is touched by accident, the work equipment may move suddenly,
and this may lead to a serious accident.

l Before standing up from the operator's seat, always place the work equipment lock lever and parking
brake lever securely at the LOCK position.

1. Stop the machine. For details. See “STOPPING THE ENGINE” on page 2-87.
2. Set parking brake lever (7) to the LOCK position to apply the park-
ing brake.

3. Move blade control lever to the LOWER position, and lower the
blade to the ground.

D51EX/PX-22 2-97
OPERATION
4. Set the work equipment lock lever (6) in the LOCK position.

CHECK AFTER FINISHING WORK

BEFORE STOPPING ENGINE
Use the meters and caution lamps to check the engine coolant temperature, engine oil pressure, fuel level, and hydraulic oil
temperature.

Remark
After work operations always allow the engine to cool down for at least five minutes in the idle (MIN) position.
Failure to do so may result in damage to the turbocharger.

CHECK AFTER SHUTING OFF ENGINE

1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, and check for leakage of
oil or coolant. If any abnormalities are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud affixed to the undercarriage or track roller system. This is especially important in colder climates.
5. Be sure the machine is parked on a dry surface to avoid any track freeze-up.

2-98 D51EX/PX-22
 OPERATION
STARTING YOUR WORK OPERATIONS
l Do not start the engine if warning tags have been attached to the control levers.
l Sound your horn to warn others in the area before starting the engine or operating the machine.
l Operate the machine in a seated position only, with the seat belt fastened snugly around your waist.
l Do not allow anyone in the cab or on the machine or it’s implements during operations.
l Check the work area to be sure all personnel are clear of the machine and your swing area.

AVOIDING DANGEROUS SITUATIONS

When using a dozer for knocking things down, such as trees, make sure
the area is clear of people, animals or objects that may be injured or
damaged.

Do not use a dozer for clearing trees or tall object unless the machine
has a protective cage installed.

Do not let personnel ride on the drawbar or any attachments.

D51EX/PX-22 2-99
OPERATION
If someone should approach you while you are operating the machine,
stop all operations immediately and signal them not to approach until
the work equipment is lowered to the ground and it is safe for them to
approach. Once they have approached, do not touch any of the machine
controls until they are away from your work area and at a safe distance.

Use extreme caution when near the edge of a cut, ditch, water or any
soft area, the edge may give way causing the machine to slide or
rollover.

When climbing a steep incline always move slowly in the lower speed
range. If the operator tries to go too fast on the hill the bulldozer may
slide causing loss of control.

Be careful when cresting the top of a hill or edge way. Always proceed
slowly when approaching these areas to avoid being jolted once the
machine breaks over the fulcrum point. Failure to do so may result in
damage to the machine or severe injury to the operator

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.

2-100 D51EX/PX-22
 OPERATION
Do not try to make a turn with the dozer on a steep slope. This could
cause the dozer to slide down the slope or possibly rollover.

If you must tow a load on a downhill grade make sure to keep the dozer
in low gear. Do not coast a bulldozer while towing a load. The chances
of the load jackknifing with the dozer become greater as the speed of the
machine increases.

When climbing down a slope, select a gear speed which actuates the
engine brake and press the brake pedal, when necessary.

HIGH VOLTAGE LINES

• When working or traveling in an area where clearances are a
problem, travel at a slow cautious speed.
• If you are not sure of your clearances, request the aid of another
person who can guide or warn you if you get too close to objects.
• Be aware of the dangers when working around overhead electrical
lines, high humidity may pose an electrical hazard even if your
machine clears the overhead power lines.
• If your machine should come in contact with overhead electrical
lines, stop the machine and remain on the machine until the power
company clears the lines and it is safe to get off or move the
machine.
• If low power lines pose a greater hazard, ask the power company to remove the lines until your work is finished.

Cable Voltage Min. Safe Distance

6.6kV 3m 10 ft.
66.0kV 5m 16 ft.
275kV 10 m 33 ft.

D51EX/PX-22 2-101
OPERATION
OPERATING THE MACHINE

PAY ATTENTION TO GAUGES

When the red range lights on the hydraulic oil temperature gauge while operating, reduce the load and wait for the temperature
to decrease.
PERMISSIBLE WATER DEPTH
When operating in water, always keep the bottom of carrier rollers
above the surface of the water. Also, be careful that the engine cooling
fan will not come in contact with water. The fan can be damaged.
After operating the machine for a long time in water, carry out greasing
of the greasing points.

METHOD OF USING BRAKES

Do not apply the center pedal suddenly when traveling at full speed.
This will cause premature wear and damage.
The decelerator pedal can be used to stop the machine using the HST
dynamic braking. (Parking brake is not applied).
The center pedal can be used to stop the machine dynamically without
reducing the engine speed. The operator will feel a sudden resistance in
the brake pedal and the pedal stroke. When the pedal is pushed further
the parking brake is applied. When the pedal is released, the machine
will return to normal.

WHEN TRAVELING UP OR DOWN HILLS

USE ENGINE AS BRAKE
When going downhill, move the travel lever into low speed to run engine at slow speed and travel down slope using the engine
as a brake.
Do not move the travel lever to the N (neutral) position.
When traveling down hills of more than 15°, shift down to 1st speed.
BRAKING WHEN TRAVELING DOWNHILL
When traveling downhill and using the braking force of the engine, use the travel lever to adjust the engine speed.
Failure to brake may result in overrunning, causing engine trouble.
Remark
When the machine travels in a straight line down a slope, the machine may deviate slightly to the left or right,
but this is caused by the actuation of the straight-travel compensation mechanism and does not indicate any
problem.

2-102 D51EX/PX-22
 OPERATION
PRECAUTIONS ON SLOPES
1. BE AWARE OF FUEL LEVEL
If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle
of the machine or the swaying of the machine. This makes the engine stop, so be careful not to let the fuel level in
the fuel tank become too low.
2. PRECAUTIONS WHEN ENGINE STOPS ON A SLOPES
If the engine stops while working or driving on a slope, the brake is applied automatically. Take care since the
machine stops suddenly at this time.

ALWAYS KEEP THE DOORS CLOSED DURING OPERATIONS

(Machines equipped with cab)
Always keep the door closed when traveling or carrying out operations.
If the door is open, there is danger of damage from obstacles or strong vibration.

DO NOT MODIFY THE CAB GLASS IN ANY WAY

(Machines equipped with cab)
l For safety reasons, do not install anything on the cab glass that will obstruct the view.
l Always keep the glass clean to ensure safety during operations.
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAYS
(Machines equipped with cab).

l The cab structure may cause blind spots.

l When operating, always be sure to check carefully for

obstacles or workers in the surrounding area.

D51EX/PX-22 2-103
OPERATION
CUTTING A GRADE
DOZING
A bulldozer digs and transports dirt in a forward direction. Slope
excavation can always be most effectively carried out by proceeding
from the top downward.

When dozing toward one side only, operate with angled blade.

BACK GRADING A SURFACE

Remark
Avoid grading on rocky or stony ground. It can damage the
blade.
To finish the ground to a flat surface after digging or leveling, put a full
load of soil in front of the blade and operate the blade up and down in
small movements while traveling forward. Finally, place the blade at
FLOAT and travel at low speed in reverse while pulling the blade over
the ground surface. Before doing this, hold the lever by hand at the
FLOAT position for at least one second to make sure that it stays in
position. To prevent damage to the blade, be careful not to travel over
any stones or rocks.
Do not apply the center pedal suddenly when traveling at full speed. This will cause premature wear and damage.
The decelerator pedal can be used to stop the machine using the HST dynamic braking. (Parking brake is not applied).
The center pedal can be used to stop the machine dynamically without reducing the engine speed. The operator will feel a
sudden resistance in the brake pedal and the pedal stroke. When the pedal is pushed further the parking brake is applied. When
the pedal is released, the machine will return to normal.

2-104 D51EX/PX-22
 OPERATION
CUTTING HARD OR FROZEN GROUND OR DITCHING
For digging and ditch excavation of hard or frozen ground, tilt the blade.
Even hard ground can be dug effectively by a tilted or angled blade.

FELLING TREES, REMOVING STUMPS

Remark
Do not uproot trees or stumps or fell trees by angling or tilting
the blade. When performing these operations be sure your
machine is equipped with the proper protection.
l Raise the blade high and push two or three times to fell the tree.
l Next, travel in reverse and push the cutting edge of the blade into
the ground to cut the roots, then push the blade in to uproot the tree.
l When doing this, never hit the tree at high speed or apply any shock
to fell the tree.

SIDE-CUTTING OPERATIONS
When carrying out side-cutting operations with the load on one side of
the blade, the work can be carried out efficiently by using
counter-rotation to correct the direction.

When cutting the bottom edge of a hill or pile always be

aware of the cut area near the hill to the side of the machine
possibly collapsing onto the machine.

D51EX/PX-22 2-105
OPERATION
UNDERCARRIAGE CARE

Undercarriage life greatly varies depending on operation method, inspection and maintenance. For most efficient operation,
keep the following points in mind.
OPERATION METHOD
l Select the track shoe that best suits the type of soil to be encoun-
tered in service.
l Consult your Komatsu distributor when selecting track shoes.
l Do not allow shoe slipping to occur during operation.
l If shoe slipping occurs, reduce load on the blade until slipping
stops.
l Avoid sudden starts, acceleration or stops, unnecessary high speeds
and sharp turns.
l Always operate machine in a straight line whenever possible. When
making turns, be careful not to allow the machine to stay to one
side, so operation in both turning directions can be done properly.
Make turns with the largest possible radius.
l Prior to operation, clear boulders and obstacles to prevent machine from riding over them while operating.
l On a slope, operate the machine parallel to the inclination of the slope. Do not operate across the slope. Also when
stopping the machine on a slope, the machine should face the top of the slope.
l When ground inclines to the left or right during digging operations, do not continue to dig with the incline. Move the
machine back to level ground and start to dig again.
l Do not force the machine to carry out work that exceeds its working capability. Such work includes cases where the idler
or sprocket come off the ground when the machine meets obstacles that resist the power of the machine during dozing or
ripping operations.

INSPECTION AND ADJUSTMENT

l Properly adjust the track tension.
l The tension should be measured at clearance (A) between the idler
and carrier roller shown in the right diagram - usually 20 to 30 mm
(0.8 to 1.2 in) at this point. For rocky terrain, tighten the tracks
slightly. In clay or sandy areas, loosen them slightly. (For
inspection and adjustment procedures. See “TRACK SYSTEM
MAINTENANCE” on page 3-31.

l Check idler rollers for oil leakage as well as for loose bolts and
nuts. If any trouble is detected, repair immediately.
l Check side clearance (S) between the idler guide plate and track
frame. If side clearance (S) increases, idler may move sideways and
the tracks may come off. (For inspection and adjustment procedure.
See “IDLER GUIDE ADJUSTMENT” on page 3-33.

2-106 D51EX/PX-22
 OPERATION
INSPECTION AND REPAIR
Frequent inspection and prompt repair will reduce repair costs.
The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Perform periodic
inspection and contact the Komatsu distributor in your area when machine has approached repairable limits and reversing
limits.
MEASURING LINK PITCH
1. Insert a wooden block between track shoe and sprocket to take up
the slack in track shoes.

2. Measure pitch length of four links in stretched portion at least two

links away for master pin. Of length obtained, 1/4 is the link pitch.
3. There is no link window on the master link.

l Basic link pitch: (P): 175.3 mm (6.9 in).

l Link pitch limit for turning: 178 mm (7.0 in).

Remark
The measured value to the right of the decimal place of link
pitch is different from the basic value depending upon the
precision of measure or the tolerance of product even if it isn't
worn out.

MEASURING HEIGHT OF GROUSER

l After taking up slack in track shoes, measure height at center of
shoe as shown below.

l Standard height (h): 55 mm (2.2 in).

l Repair limits: 25 mm (1.0 in).

D51EX/PX-22 2-107
OPERATION
MEASURING OUTSIDE DIAMETER OF TRACK ROLLER
1. Measure the height (dimension C) of the link tread as shown in the
diagram.
2. Stop machine at position where link tread, whose size C has been
measured completely, contacts roller tread. Then measure size B.
3. Calculate outside diameter of tread (size A):
l A = (B - C) x 2

l Standard size (h): 185 mm (7.3 in)

l Repair limits: 160 mm (6.3 in)

2-108 D51EX/PX-22
 OPERATION
TRANSPORTING THE MACHINE
Before transporting the machine be sure what you are using to transport the machine is capable of supporting the weight of the
machine. Be sure it is wide enough and rated for the load.

LOADING OR UNLOADING A TRAILER

Select the trailer to match the weight and dimensions given in See “SPECIFICATIONS” on page 4-2.

l Since loading and unloading of the machine is dangerous, be extremely careful.

l When loading or unloading the machine, operate it slowly with the engine speed low and the speed
range at 1st or less.

l Use ramps having sufficient width, length, thickness, and strength. Install them securely and set their
angle to 15° or less.

l If the ramps are deflected appreciably, reinforce them with blocks.

l Perform the loading work of the machine on firm, level ground. Secure sufficient distance between the
shoulder of the road and the trailer.

l Remove mud from the undercarriage of the machine the machine will not slip sideways on the ramps.
In addition, remove water, snow, ice, grease, oil, etc. from the ramps.

l Never steer the machine on the ramps, since steering on the ramps can cause the machine to tip over.
If it is necessary to change the travel direction, return to the ground or to the bed of the trailer, then
change the travel direction.

l The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and
the machine is unbalanced and becomes dangerous. Accordingly, pass the border slowly.

1. Always load on level stable ground using the properly sized ramps with the trailer wheels chocked. Maintain a safe
distance from the edge of the road.
2. Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move. Then firmly
attach the ramps in line with the centers of the trailer and the machine.

D51EX/PX-22 2-109
OPERATION
3. Make sure that both ramps are at the same level. Make the slope of the ramps a maximum of 15º. Set the distance between
the ramps to match the center of the tracks.

4. Start the engine.

l In a cold weather, carry out an engine warming-up run,
referring to the section, See “COLD WEATHER STARTS” on
page 2-80 in this manual.
5. Set parking brake lever to the FREE position.
6. Use the variable mode to set the speed range to 1st or less, and
travel slowly.
7. Set the travel direction toward the ramps and drive slowly.
l The center of gravity of the machine shifts suddenly at the
border between the ramps and trailer, and the machine is
unbalanced and becomes dangerous. Accordingly, pass
the border slowly.
8. Stop the machine at the specified position on the trailer.

PRE-TRANSPORTATION PROCEDURES
Remark
The mass and dimensions for transportation shown in SPEC-
IFICATIONS depend on the types of shoe, blade, etc.

1. Lower the blade to the ground and set it horizontal to the ground
surface.
2. Remove the blade assembly.

Machine mode (A) mm (ft in) (B) mm (ft in)

D51EX 3,045 (10’) 2,725 (8’11”)
D51PX 3,350 (11’) 2,990 (9’10”)

Remark
The overall width can be reduced by angling the blade to the maximum. Determine whether or not it is
necessary to detach the blade for transportation, referring to the drawing on the right.
REMOVING CAB
If it is necessary to remove the cab for transportation. Machine cannot be operated without cab. Contact your Komatsu distri-
butor.

2-110 D51EX/PX-22
 OPERATION

SECURING MACHINE

When the edge of the blade protrudes beyond the trailer, angle the blade.

Remark
Always loosen the screw at the rotating portion and set the
radio (machine equipped with cab) antenna facing down.
l Load the machine onto a trailer as follows:
A. Lower the work equipment slowly.

B. Set the work equipment lock lever (6) to the LOCK position.

C. Set the parking brake lever (7) to the LOCK position.

D. Turn the ignition switch to the OFF position to stop the engine,
and pull out the ignition switch key.

D51EX/PX-22 2-111
OPERATION
E. Secure the machine as explained below so that it will not move
during transportation.

l In particular, fix the machine securely to prevent it from

slipping sideways.
F. Put blocks (1) in front and behind the track shoes of both sides.

G. Set up chain or wire, following (A) or (B).

l A: Secure chain or wire around the track shoes.

l B: Secure chain or wire through the holes of track frame.
H. Protect the wire from contacting directly with any sharp edges
the machine, by inserting pads.

UNLOADING THE MACHINE

1. Always unload on level stable ground using the properly sized ramps with the trailer wheels chocked. Maintain a safe
distance from the edge of the road.
2. Load and unload on firm level ground only.
3. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving.
Set left and right ramps (2) parallel to each other and equally spaced to the left and right of center (3) of the trailer. Set the
angle of installation (4) a maximum of 15o. If the ramps bend a large amount under the weight of the machine, put blocks
under the ramps to prevent them from bending.
4. Remove the chains and wire ropes fastening the machine.
5. Start the engine.
l In cold weather, warm up the engine. See “COLD WEATHER STARTS” on page 2-80 in this manual.
6. Set the work equipment lock lever to the FREE position.
7. Raise the blade.
8. Set parking brake lever to the FREE position.
l Use the variable mode to set the speed range to 1st or less, and travel slowly.
9. Set the travel direction toward the ramps and drive slowly.
l The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and the machine is
unbalanced and becomes dangerous. Accordingly, pass the border slowly.
10. Drive down the ramps slowly and carefully until the machine leaves the ramps completely.

2-112 D51EX/PX-22
 OPERATION
LIFTING THE MACHINE

l The operator carrying out the lifting operation using a crane must be a properly qualified crane
operator.

l Never raise the machine with any worker on it.

l Always make sure that the wire rope is of ample strength for the weight of this machine.

l When lifting, keep the machine horizontal.

l When carrying out lifting operations, set the lock lever to the LOCK position to prevent the machine
from moving unexpectedly.

l Never enter the area under or around a raised machine.

l Never try to lift the machine in any posture other than the posture given in the procedure below or
using lifting equipment other than in the procedure below. There is a hazard that the machine may
lose its balance.

Remark
The lifting method differs according to the attachments and options installed. In such cases, contact your
Komatsu distributor for information.

l For details of the weight. See “SPECIFICATIONS” on page 4-2.

When lifting the machine, carry out the operation on flat ground as
follows.

1. Stop the engine and set the parking brake lever to the LOCK
position.
l Use a wire rope and sling that matches the weight of the
machine.
2. Pass the wire rope under the track frame at the point where the
machine is to be lifted.
l Use protectors, etc. so the wire ropes will not be broken at
sharp edges or narrow places.
l Use spreaders and bars having sufficient width so they will not
touch the machine.
3. After setting the wire ropes, lift up the machine and stop at 100 to
200 mm (3.9 to 7.9 in) above the ground, and check to be sure wire
ropes are not slack and the machine is level, then lift up slowly.

D51EX/PX-22 2-113
OPERATION
COLD WEATHER OPERATION
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.

FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components. For details of the specified viscosity. See “RECOMMENDED
FUEL, COOLANT, AND LUBRICANT” on page 3-11.

COOLING SYSTEM COOLANT

Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or
on your skin, wash it off with large quantities of fresh water and see a doctor at once.
Be extremely careful when handling it. When replacing coolant containing antifreeze or when handling
coolant when repairing the radiator, contact your Komatsu distributor or ask your local antifreeze dealer.
Be careful not to let the coolant flow into drainage ditches or spray on to the ground surface.

Remark
Please use Komatsu genuine supercoolant (AF-NAC) for the coolant. As a basic rule, we do not recommend
the use of any coolant other than Komatsu genuine supercoolant (AF-NAC).

For details of the antifreeze mixture when changing the coolant. See “CLEAN COOLING SYSTEM” on page 3-27.

2-114 D51EX/PX-22
 OPERATION
BATTERY

The battery generates flammable gas, so do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of
water, and consult a doctor.
Battery electrolyte dissolves paint. If it gets on to the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is danger that the battery may explode.

Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.

When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the battery
electrolyte may freeze. Maintain the battery charge as close as possible to 100%, and insulate it against cold temperature so the
machine can be started easily the next morning.
Remark
Measure the specific gravity and calculate the rate of charge from the following conversion table.

Electrolyte temp
20ºC 0ºC -10ºC -20ºC
Rate of charge
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26

l Because the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine. Keep
it in a warm place overnight, and install it again the next morning.

D51EX/PX-22 2-115
OPERATION
PRECAUTIONS ON PARTICULAR JOBSITES
l When carrying out dozing operations in water, if the work equipment mounting pin goes into the water, grease it every
time it comes out of the water.
l For heavy-duty operations, grease the work equipment mounting pins every time before each operation.

DISCHARGED BATTERY

It is dangerous to charge the battery while it is still mounted

on the machine. Always remove the battery before charging
it.
When checking or handling the battery, stop the engine and
turn the ignition switch key to the OFF position.
The battery generates hydrogen gas, so there is danger of
explosion.
Do not bring lighted cigarettes near the battery, or do
anything that will cause sparks.
Battery electrolyte is diluted sulfuric acid, and it will attack
your clothes and skin. If it gets on your clothes or on your
skin, wash it off immediately with large amounts of water. If it
gets into your eyes, wash it out with fresh water, and consult
a doctor.
When handling batteries, always wear protective goggles
and rubber gloves.
When removing the battery, first disconnect the cable from
the ground (normally the negative (-) terminal). When
installing, install the positive (+) terminal first.
If a tool touches the positive terminal and the chassis, there
is danger that it will cause a spark, be extremely careful.
If the terminals are loose, there is danger that the defective
contact may generate sparks that will cause an explosion.
When installing the terminals, install them tightly.
When removing or installing the terminals, check which is
the positive (+) terminal and which is the negative (-)
terminal.
Green rust around the terminals is a cause of self-discharge
of the battery. Clean the terminals with sandpaper. After
removing the rust, coat the terminals thinly with dielectric
grease before installing.

2-116 D51EX/PX-22
 OPERATION
REMOVE AND INSTALL BATTERY
1. Open the battery cover (1), then remove bolts (3) of the tool box
support. Remove hold downs (2) of the battery mounting holder.
2. Before removing battery, remove the ground cable (normally
connected to the negative (-) terminal). If any tool touches between
the positive terminal and the chassis, there is danger of sparks being
generated. Loosen the nuts of the terminal and remove the wires
from the battery.
3. Remove hold down bracket assembly.
4. Remove battery from tray.

5. After installing the battery, secure it with the battery hold down.
l Tightening torque: 3.92 to 5.88 Nm (2.9 to 4.3 lb/ft).
6. When installing the battery, connect the ground cable last.
7. Install the terminal on the battery and tighten the nut.
l Tightening torque: 5.9 to 9.8 Nm (4.3 to 7.2 lb/ft).

BATTERY CHARGES
When charging the battery, there is danger that the battery may explode
if it is mishandled. Follow the instructions in “ELECTRICAL SYSTEM
PROBLEMS” on page 2-125 and the instruction manual supplied with
the charger, and be sure to observe the following precautions.
1. Set the voltage of the charger to match the voltage of the battery to
be charged. If the voltage is not selected correctly, the charger may
overheat and cause an explosion.
2. Connect the positive (+) charger clip of the charger to the positive
(+) terminal of the battery, then connect the negative (-) charger clip
of the charger to the negative (-) terminal of the battery. Be sure to
connect the clips securely.
3. Set the charging current to 1/10 of the value of the rated battery
capacity; when doing rapid charging, set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and
explode.
4. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a danger that this will ignite the battery electrolyte and cause the battery to explode.
5. Do not use or charge the battery if the battery electrolyte level low. This may cause an explosion.

D51EX/PX-22 2-117
OPERATION
STARTING ENGINE WITH BOOSTER CABLES
When starting the engine with a booster cable, do as follows.
CONNECTING AND DISCONNECTING BOOSTER CABLES

When connecting the cables, never contact the positive (+) and negative (-) terminals.
When starting the engine with a booster cable, always wear safety glasses.
Be careful not to let the normal machine and problem machine contact each other. This prevents sparks
from generating near the battery which could ignite the hydrogen gas given off by the battery. If hydrogen
gas explodes, it could cause serious injury.
Make sure that there is no mistake in the booster cable connections. The final connection is to the upper
structure frame, but sparks will be generated when this is done, so connect to a place as far as possible
from the battery. (However, avoid connecting the cable to the work equipment, as conduction is poor).
Use care when removing the cables from a machine that has been started. To avoid hydrogen explosion,
do not allow the cable ends to contact each other or the machine.

Remark
The starting system for this machine uses 24 Volts. For the normal machine, use a 24V system.
The size of the booster cable and clip should be suitable for the battery size.
The battery of the normal machine must be the same capacity as that of the engine to be started.
Check the cables and clips for damage or corrosion.
Make sure that the cables and clips are firmly connected.
Check to be sure the safety lock levers are in the LOCK position.
Check to be sure each lever is in the NEUTRAL position.
Before connecting two machines with booster cables, turn off the troubled machine’s battery disconnect switch
and take out the battery disconnect switch key in order to prevent damages to the eletrical system of the
machine.

2-118 D51EX/PX-22
 OPERATION
BOOSTER CABLE CONNECTION
Before connecting two machines with booster cables, turn the troubled
machine’s starting switch and battery disconnect switch to the OFF
position and then switch off the normal machine’s starting switch. Con-
nect booster cables in numerical order as shown in the illustration.
Connect the booster cable as follows, in the order of the numbers
marked in the diagram.
1. Make sure that the ignition switches of the normal machine and
problem machine are both at the OFF position.
2. Connect one clip of booster cable (A) to the positive (+) terminal of
the problem machine.
3. Connect the other clip of booster cable (A) to the positive (+) termi-
nal of the normal machine.
4. Turn on the troubled machine´s battery disconnect switch (S). Lastly, connect one clip of booster cable (B) to the negative
(-) terminal of the normal machine.
5. Connect the other clip of booster cable (B) to the upper structure of the problem machine.

STARTING THE ENGINE

Always check to be sure the parking brake lever is set to the LOCK position, regardless of whether the
machine is working normally or has failed. Also check to be sure all the control levers are at the HOLD or
neutral position.

1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and keep it to running at high idling speed.
3. Turn the ignition switch of the problem machine to the START position and start the engine. If the engine doesn't start at
first, try again after two minutes or so.

BOOSTER CABLE DISCONNECTION

After the engine has started, disconnect the booster cables in the reverse
order in which they were connected.
1. Remove one clip of booster cable (B) from the upper structure of
the problem machine.
2. Remove the other clip of booster cable (B) from the negative (-) ter-
minal of the normal machine.
3. Remove one clip of booster cable (A) from the positive (+) terminal
of the normal machine.
4. Remove the other clip of booster cable (A) from the positive (+)
terminal of the problem machine.

D51EX/PX-22 2-119
OPERATION
GENERAL TROUBLESHOOTING

AFTER RUNNING OUT OF FUEL

When restarting the machine after running out of fuel, fill with fuel and bleed the air from the fuel system before starting.
For details of bleeding the air. See “REPLACE PRE AND MAIN FUEL FILTER CARTRIDGES” on page 3-60.

TOWING THE MACHINE

l If the engine will not start, place blocks under the tracks to prevent the machine from moving, then
release the brakes. If blocks are not put under the tracks, the machine may suddenly move.

l Be sure to use wire rope sufficiently strong enough for the towing weight.

l When using the towing hook, be sure to use a shackle.

l Set the wire rope horizontally and align it with the track frame.

l Tow the machine slowly.

l When returning a towed machine to the job site, first check to be sure the necessary repairs or
adjustments have been made.

For details of the method of towing, contact your Komatsu distributor.

l With this machine, if the engine stops or there is a problem in the hydraulic system and the oil pressure in the brake circuit
drops, the brake is actuated to prevent the machine from moving. To move the machine, it is necessary to use a special
device to set the oil pressure in the brake circuit to above the specified pressure. Contact your Komatsu distributor.
l Moving a machine by towing is only used to move it to a place where it is possible to carry out inspection and
maintenance. It is not intended for moving the machine long distances. Do not use this method for towing the machine for
long distances.
l Before towing, check to be sure tow rope or bar are in good condition, and that they have ample strength for the towing
operation. If the machine being towed may get stuck in mud or may have to be towed uphill, the tow rope or bar must be
of a strength of at least 1.5 times greater than the weight of the machine being towed.
l If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on the machine.
l To protect the operator if the towing rope or bar should break, fit a shield to the machine being towed.
l When towing a machine, travel slowly. If the machine is suddenly pulled, the towing rope may break. Before starting to
move the towed machine, remove any slack in the rope, and keep the rope taut during the towing operation.
l Keep the angle of the towing line to the minimum. Operate the
machine so the angle does not become greater than 30° from the
straight line
l If the machine gets stuck in the mud or a heavy thing needs to be
towed, install a towing wire rope to the draw bar pin.

2-120 D51EX/PX-22
 OPERATION

WHEN IT IS POSSIBLE TO START ENGINE

The operator of the machine being towed should always operate the steering so the machine faces in the
direction of the towing line.

If the brake system is able to be released and the engine is able to run, it is possible to pull the machine out of mud, move it to
the side of the road, or tow it for short distances.
Carry out the operation extremely carefully.

WHEN ENGINE DOES NOT START

l If action has been taken to release the brakes, the brakes cannot be used, so never let anyone travel
on the machine when it is being towed.

l When towing a machine downhill, connect another machine behind the machine being towed and use
the brakes on this machine to control the braking.

l When carrying out the towing operation, do not let any person enter the area around the machine
being towed.

If the engine does not work and the machine is to be moved, it is necessary to carry out preparatory work to install a pump to
release the brakes.
For details of the equipment needed to tow a machine when the engine does not work, contact your Komatsu distributor.
(Part number of service pump: 790-190-1500)
To release the brakes, install a brake release pump on the machine to be towed and connect the hose at the pressure side of the
pump to the solenoid block. Use the pressure of the pump to apply pressure to the brake circuit to release the brakes.

RELEASING THE BRAKES

l It is possible to use a service hydraulic pump M1 and nipple M2 to
release the brakes on the problem machine to tow it.
l Main specifications of hydraulic pump.
l Discharge amount: 25 cc/stroke.
l Discharge pressure: 60 kgf/cm2 (852.0 PSI).
l Tank capacity: 20 liters (5.28 US gal).
l Oil used: SAE10W.
l Weight: 9.5 kg (20.95 lb).
l Hose length: 1.5 m (59.1 in).
PUMP TEST
If the operation is carried out without inspecting the hydraulic pump, it
may lead to damage of the brake system seal. Always inspect the hydraulic pump before connecting it.
l Install tee (1) to the discharge portion of the pump, then install oil pressure gauge (2) and rubber hose (3).
l Install quick coupler (4) to the end of rubber hose (3) that is mounted to the machine.
l Pump handle (5) and check to be sure pressure gauge will measure: 2.7 to 3.1 MPa (298 to 454 PSI).
l If it is necessary to move the brake release pump during the operation, hold lever (6) under handle (5) and move the
pump as needed.

D51EX/PX-22 2-121
OPERATION
CONNECTING PUMP TO MACHINE

l Immediately after the engine is stopped, all parts are at high temperature, do not carry out the
operation to install the brake release pump immediately. Wait for the temperature to go down until it is
possible to touch the pump by hand.

l Install blocks securely under the tracks to prevent the machine from moving.

1. Remove floor mat and floor cover plate.

2. Loosen locknuts (a) on the towing valves (1) for the left pump and
(2) for the right pump. Once the lock nuts are loose, back the
towing valves (1) and (2) out by two turns.
3. Tighten locknuts (a) lightly to hold the valves in position so that
they do not move during the towing operation.

4. Install pump assembly M1 onto the floor frame of the machine.

5. Loosen plug (5) and bolt (6) of the motor control valve and swing
lock plate (7)from union (5). Retighten plug (5) down until it stops.
Tighten bolt (6) so it will not come off when the machine is towed.
6. Remove plug (8) and install nipple M2.

2-122 D51EX/PX-22
 OPERATION
7. After installing nipple M2 in plug port (8), connect the quick
coupler at the end of the pump assembly M1 to nipple M2.

A. Close the valve on pump [1] and operate the handle to supply
oil to the parking brake circuit.

B. Increase the supply pressure until relief valve [2] relieves once.

l Specified relief pressure: 28 to 32 kg/cm2 (398 to 455 PSI)

l If the supply pressure rises above the specified relief pressure,
the brake piston of the HST motor may be damaged.
l If the supply pressure should exceed the specified relief
pressure, open the valve on the pump immediately and adjust
the relief pressure.
l If the supply pressure reaches the specified relief pressure, the
parking brake is released.
8. Remove the block of the track shoe and tow the machine at speed lower than 2 km/h.
l If the supply pressure goes below 15 kg/cm2 (214 PSI), the parking brake will not be released completely. Keep
checking oil pressure gauge [4] while towing the machine. If the oil pressure lowers, operate the handle to maintain
the oil pressure in the range of 15 to 32 kg/cm2 (215 to 455 PSI).
l After towing the machine to a safe place, open the valve [2] on the pump to release the pressure supplied to the
parking brake circuit.

Remark
When towing the machine, it is important to monitor the brake pressure with the ignition key in the “ON”
position and the monitor in Real Time Monitoring mode (91902). Do not let the pressure drop below 15 to 32
kg/cm2 (215 to 455 PSI) on the monitor panel.

D51EX/PX-22 2-123
OPERATION
AFTER TOWING MACHINE
After towing the machine to a safe place, take the following steps immediately to return the machine to the condition before
towing.
A. Remove pump assembly M1 and nipple M2 and install plug (8).

B. Loosen plug (5) of the 5-spool valve and return lock plate (7) to original position and then tighten plug (5) and bolt
(6) to secure lock plate (7).

C. Return plugs (4) of towed valves (1) and (2) of the HST pump and secure them with locknuts (3).

D. Install the floor plate.

l Plug and locknut: 24.5 – 34.3 Nm (18 - 25 ft/lbs)

2-124 D51EX/PX-22
 OPERATION
ELECTRICAL SYSTEM PROBLEMS
l (): Always contact your Komatsu distributor when dealing with these items.
l In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs.

Problem Main causes Remedy

Lamp does not glow brightly even when l Defective wiring, deterioration of l (Check, repair loose terminals,
the engine runs at high speed. battery disconnections, replace battery)
Lamp flickers while engine is running. l Loose belt l Check belt tension, replace
Charge level monitor does not go out l Defective alternator l (Replace)
even when engine is running. l Defective wiring l (Check, repair)
l Defective alternator belt l (Service or replace0
Abnormal noise is generated from
l Defective alternator l (Replace)
alternator.
Starting motor does not turn when l Defective wiring
ignition switch is turned to START l (Check, repair)
l Defective starting motor
position. l (Replace)
l Insufficient battery charge
l Charge
l Battery disconnect switch is in the
l Turn the switch to ON position.
OFF position.
Drive in starter motor operates l Insufficient battery charge l Charge
intermittently. l Defective safety relay l (Replace)
Starting motor turns engine sluggishly. l Insufficient battery charge l Charge
l Defective starting motor l (Replace)
Starting motor disengages before engine l Defective wiring, defective ring l (Check, repair)
starts. gear pinion
l Insufficient battery charge l Charge
Pre-heating monitor does not light. l Defective wiring l (Check, repair)
l Defective heater relay l (Replace)
Outside of the electrical heater is not l Defective wiring l (Check, repair)
warm when touched by hand. l Open in electrical heater l (Replace)
l Defective heater relay or switch l (Replace)
Air conditioner does not work properly. l Blown fuse l (Check repair)
l Low battery charge l Charge
l Defective A/C switch l (Replace A/C switch)
l Defective blower switch l (Replace switch)
l Defective A/C compressor l (Replace compressor)
l Low refrigerant charge l (recharge system)

D51EX/PX-22 2-125
OPERATION

MONITOR PANEL
When an action code appears on the display panel B (multi-informa-
tion), take appropriate remedies based upon the table below.
l (1): Display panel.
l (2): Warning lamp (red).

If different kinds of failures occur at the same time, their action codes
are arranged in the order of seriousness in the display.
The order of seriousness in this case is E04, E03, E02 and E01, starting
from the most serious one.

Action Warning Alarm

Display panel B
code
Top line: Displays E01 Bottom line:
E01
Displays service meter.
Top line: Displays E02 Bottom line:
E02
Displays service meter.
Top line: Displays E03 Bottom line:
E03 Displays telephone number (If no
telephone number is set, displays 0).
Top line: Displays E04 Bottom line:
Displays telephone number.
E04
(If no telephone number is set,
displays 0).
Remedy
lamp buzzer
Part of function has failed or stopped, but
operations can be carried out safely.
⎯ ⎯
However, after completing operations,
contact your Komatsu distributor for repairs.
Serious failure in part of function, stops.
When continuing operations, be extremely
Flashes Sounds careful of location of failure. After
completing operations, contact Komatsu
distributor for repairs.
After moving to safe place, stop machine
Flashes Sounds immediately. Contact Komatsu distributor
for repairs.
Stop machine immediately. Contact Komatsu
Flashes Sounds
distributor for repairs.

l If an action code appears on display panel B, check the failure code. For details. See “USING FAILURE CODE DIS-
PLAY” on page 2-26.
l When contacting your Komatsu distributor, please give the failure code also.

2-126 D51EX/PX-22

CHASSIS PROBLEMS
l (): Always contact your Komatsu distributor when dealing with these items.
l In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem
When brake pedal is depressed,
machine does not stop.
Track comes off.
Abnormal wear of sprocket.
Blade, rise slowly, does not rise.
Does not steer even when steering
is operated.
Noise is generated from idler.
Lacks drawbar pull (cannot travel
at full speed).
Travel speed does not rise quickly.
Machine does not move off when
travel lever is placed in gear.
Only one track operates.
Machine turns when steering is not
operated
HST oil temperature overheats
(indicator enters red range)
D51EX/PX-22
Main causes
l Defective adjustment of brake
limit switch
l Track too loose
l Track too loose or too tight
l Lack of hydraulic oil
l Work equipment lock lever in
LOCK position
l Wear, scuffing of charge pump
l Defective work equipment PPC
valve
l Parking brake lever in LOCK
position
l Wear, scuffing of charge pump
l Defective EPC valve of HST
pump
l Lack of oil in idler
l Lack of drive power from engine
l Defective HST pump, motor
l Low temperature of HST oil
l Parking brake lever in LOCK
position
l Wear, scuffing of charge pump
l Does not work brake release
solenoid
l Defective BPC valve of HST
pump
l Defective electrical connection
l Defective travel lever
l Defective HST pump motor
l Defective motor rotation sensor
l High load at less than full engine
speed
l Excessive load when
operating
l Clogged oil cooler fins
OPERATION
Remedy
l (Adjust, check, repair)
l Adjust track tension, see WHEN
REQUIRED
l Add oil to specified level, See
“CHECKING AND ADDING OIL TO
HYDRAULIC TANK” on page 2-65
l Set lever in free position
l (Check, repair)
l (Check, repair)
l Set lever in free position
l (Check, repair)
l (Check, repair)
l Add oil to specified level, see See “” on
page 3-20
l See ENGINE
l (Check, repair)
l Warm up machine
l Set lever in free position
l (Check, replace)
l (Check, repair, replace)
l (Check, replace)
l (Check, repair, replace)
l (Adjust, check, repair)
l (Adjust, check, repair, replace)
l (Adjust, check, replace)
l Increase engine speed reduce transmis-
sion setting.
l Reduce load or duty cycle.
l (Clean or repair, See “EVERY 500
HOURS MAINTENANCE” on page 3-
61)
2-127
OPERATION
ENGINE PROBLEMS
l (): Always contact your Komatsu distributor when dealing with these items.
l In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs.

Problem Main causes Remedy

Engine oil pressure monitor lights up
even if engine speed is raised after
warm up
Steam spurts out from top of radiator
(pressure valve).
Engine coolant temperature caution
lamp flashes
Engine does not start when starting
motor is turned.
Exhaust gas is white or blue.
Exhaust gas occasionally turns black.
Combustion noise occasionally make
breathing sound.
l Engine oil pan oil level is low
(sucking in air)
l Clogged oil filter cartridge
l Defective tightening of oil pipe,
pipe joint, oil leakage from dam-
aged point
l Defective monitor
l Cooling level low, leakage of
coolant
l Loose fan belt
Dirt or scale accumulated in
cooling system
l Clogged radiator fins
l Defective thermostat
l Loose radiator fill cap (high alti-
tude)
l Defective monitor panel
l Lack of fuel
l Air in fuel system
l Defective fuel injection pump or
defective nozzle
l Starting motor cranks engine
sluggishly
l Poor compression
l Defective valve clearance
l Too much oil in oil pan
l Improper fuel
l Clogged air cleaner element
l Defective nozzle
l Defective compression
l Defective turbocharger
l Defective nozzle
l Lack of fuel (air in fuel)
l Add oil to specified level, see “WARN-
ING ALERTS” on page 2-10
l Replace cartridge, see “EVERY 500
HOURS MAINTENANCE” on page 3-
54
l (Check, repair)
l (Replace)
l Check, add coolant, repair, see
“WARNING ALERTS” on page 2-10
l Check fan belt tension, adjust, replace
Change coolant, flush inside of cooling
system, see “” on page 3-20
l Clean and repair, see EVERY 500
HOURS SERVICE
l Replace thermostat
l Tighten or replace cap
l (Repair)
l Add fuel, see “STARTING THE
ENGINE” on page 2-79
Repair place where air is sucked in, see
(Replace pump or nozzle)
l See “ELECTRICAL SYSTEM PROB-
LEMS” on page 2-125
l (Adjust valve clearance)
l Set oil to specified level, see “PRE-
OPERATIONAL CHECKS” on
page 2-62
l Change to specified fuel
l Clean or replace, see “” on page 3-20
l (Replace nozzle)
l (See defective compression above)
l Clean or replace turbocharger
l (Replace nozzle)
l Add fuel (bleed air)

2-128 D51EX/PX-22

Problem Main causes
l Low-grade fuel being used
l Overheating
Abnormal noise generated
(combustion or mechanical).
l Damage inside muffler
l Excessive valve clearance
D51EX/PX-22
OPERATION
Remedy
l Change to specified fuel
l Refer to Radiator coolant temperature
is in the red range
l Replace muffler
l (Adjust clearance)
2-129
OPERATION
LONG TERM STORAGE

BEFORE STORAGE
l When keeping in long-term storage (more than one month), store as follows.
l Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level ground and
cover the machine with a tarp.
l Completely fill the fuel tank. This prevents moisture from collecting.
l Lubricate and change the oil before storage.
l Apply a thin coat of grease to metal surface of the hydraulic piston cylinder rods and the idler adjusting rods.
l Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
l Place all control levers in the neutral position, set the work equipment lock lever and parking brake lever in the LOCK
position, and set the fuel control lever to the low idle position.
l To prevent rust, fill with Komatsu genuine supercoolant (AF-NAC) to give a density of at least 30% for the engine
coolant.
l After shutting off the engine, wait over one minute, then turn the battery disconnect switch to the OFF position and take
out the battery disconnect switch key. Put a cover on the battery during storage.
l

DURING STORAGE

If it is necessary to perform the following rust-prevention operation while the machine is indoors, open the
doors and windows to improve ventilation and prevent gas poisoning.

l During storage, operate and move the machine for a short distance once a month so that a new film of oil will coat moving
parts. At the same time, also charge the battery.
l When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
l If the machine is equipped with an air conditioner, operate the air conditioner for three to five minutes once a month to
lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing this. In addition, check
the refrigerant level twice a year.

AFTER STORAGE
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor
before using it.
When using the machine after long-term storage, do as follows before using it:
l Wipe off the grease from the hydraulic cylinder rods.
l Add oil and grease at all lubrication points.
l When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after start-
ing the engine. If there is water in the oil, change all the oil.

Remark
Even when the key in the starting switch of the KOMTRAX system equipped machine is at the OFF position, a
small amount of electric power is consumed. When putting the machine into storage for one or more months,
follow the instructions set forth in “LONG TERM STORAGE” on page 2-130. When storing the machine for a
long time, first turn the starting switch to the OFF position, wait over one minute, then switch off the battery dis-
connect switch, and take out the battery disconnect switch key. By switching off the battery disconnect switch,
battery drain can be reduced. Note however that it stops KOMTRAX functioning at the same time.
2-130 D51EX/PX-22
 OPERATION
MACHINES EQUIPPED WITH KOMTRAX SYSTEMS
l KOMTRAX is a machine management system that uses wireless communication.
l A contract with your KOMATSU distributor is necessary before KOMTRAX system can be used. Any customers who
would like to add KOMTRAX to their machine must consult with their KOMATSU distributor.
l The KOMTRAX equipment is a wireless device that uses radio waves, it is necessary to obtain authorization and
conformation regarding the laws of the country or location where the machine equipped with KOMTRAX is used. Always
contact your KOMATSU distributor before selling or exporting any machine equipped with a KOMTRAX system.
l If you do not obey the above precautions, neither KOMATSU nor your distributor can take any responsibility for any
problems caused.

BASIC PRECAUTIONS

l Never disassemble, remove repair modify or move the communications terminal, antenna or cables.
This may cause failure or a fire in the KOMTRAX system. Always consult with your KOMATSU dealer
before making any changes to the KOMTRAX system.

l Do not allow the wiring or cables in the KOMTRAX system to become damaged. This may damage the
KOMTRAX system or cause a fire.

l For anyone wearing a pacemaker, make sure the communications antenna is at least 22 cm (8.7 in)
away from the pacemaker. The radio waves may have adverse effects on the operation of the
pacemaker.

When the key is in the ignition switch of the KOMTRAX equipped system and is turned OFF, a small amount of electrical
power is consumed.
Contact your KOMATSU distributor before installing a top guard or other attachment that covers the cab roof.
Be careful not to get water on the communications terminal or wiring.
Remark
The KOMTRAX system uses wireless communication so it cannot be used inside tunnels, underground, inside
buildings or in mountainous areas. Even if the machine is outside and there is no communication signals in
your area, the system will not operate.
There is no need to inspect or test the KOMTRAX system during a Pre-operation test or general
maintenance. However, if the system should fail, contact your KOMATSU distributor.

D51EX/PX-22 2-131
OPERATION

2-132 D51EX/PX-22
 MAINTENANCE 3

D51EX/PX-22 3-1
MAINTENANCE
MAINTENANCE INFORMATION
Do not perform any inspection and/or maintenance operation that is not found in this manual.

SERVICE METER READING

Check the service meter reading every day to see if the time has come for any necessary maintenance.

KOMATSU GENUINE REPLACEMENT PARTS

Use Komatsu genuine parts specified in the Parts Book as replacement parts.

KOMATSU GENUINE LUBRICANTS

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature.

WINDSHIELD WASHER FLUID

Use automobile windshield washer fluid, and be sure not to let any dirt get into it.

FRESH AND CLEAN LUBRICANTS

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from oil and
grease.

CHECK DRAINED OIL AND USED FILTER

After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If large
quantities of metal particles or foreign materials are found, report to the person in charge, and correct the situation.

FUEL STRAINER
Your machine is equipped with a fuel strainer, do not remove it while fueling.

WELDING INSTRUCTIONS
l Before starting welding work, turn the starting switch to the OFF position, wait over one minute, then switch off the
battery disconnect switch and take ou the battery disconnect switch key.
l Turn off the engine ignition switch.
l Disconnect the negative battery cable.
l Do not apply more than 200V continuously.
l Connect grounding cable within 1 m (3.3 ft) from the area to be welded. If grounding cable is connected near instruments,
connectors, etc., the instruments may malfunction or fail.

3-2 D51EX/PX-22
 MAINTENANCE
l Avoid having seals or bearings between the area to be welded and the position of grounding point.
l Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
DO NOT DROP THINGS INSIDE MACHINE
l When opening inspection windows or the oil filler port of the tank, be careful not to drop nuts, bolts, or tools inside the
machine.
If such things are dropped inside the machine, it will cause damage, machine malfunction, and will lead to failure. If you
drop anything inside the machine, remove it immediately.
l Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.

DUSTY JOBSITE
When working at dusty worksites, do as follows:
l Check the clogging of the air cleaner more frequently with the dust indicator. Clean the air cleaner element more
frequently.
l Clean the radiator core frequently to avoid clogging.
l Clean and replace the fuel filter frequently.
l Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
l When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting into the
oil.

AVOID MIXING LUBRICANTS

Never mix different kinds of oil. If a different type of oil has to be added, drain the old oil and replace all the oil with the new
type of oil.

HYDRAULIC SYSTEM - AIR BLEEDING

When hydraulic equipment has been repaired or replaced, or the hydraulic piping has been removed and installed again, the air
must be bled from the circuit. For details, see “BLEEDING AIR FROM PUMP” on page 3-42.

HYDRAULIC HOSE INSTALLATION

l When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and replace with
new parts. When doing this, be careful not to forget to assemble the O-rings and gaskets.
l When installing the hoses, do not twist them or bend them into loops with a small radius. This will cause damage to the
hose and markedly reduce its service life.

CHECKS AFTER INSPECTION AND MAINTENANCE WORKS

If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to
serious injury or property damage. Always do as follows.
1. Checks after operation (with engine stopped).
l Have any inspection and maintenance points been forgotten?
l Have all inspection and maintenance items been carried out correctly?
l Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped inside the
machine and get caught in the linkage mechanism.

D51EX/PX-22 3-3
MAINTENANCE
l Are there any water or oil leaks? Have all the bolts been tightened?
2. Checks when operating engine
l For details of the checks when operating the engine, see “GENERAL SAFETY RULES AND PRECAUTIONS” on
page 1-7 and pay careful attention to safety.
l Are the inspection and maintenance items working properly?

LOCKING THE INSPECTION COVER

Lock inspection cover securely into position with the lock bar. If inspection or maintenance is performed with inspection cover
not locked in position, there is a danger that it may be suddenly blow shut by the wind and cause injury to the worker.

OPENING OR CLOSING RADIATOR GRILL

l Remove the two lower grill bolts (1) and the two lower grill frame
bolts (3) and remove the lower part of the grill.

Do not separate the grill assembly from the fan assembly.

Doing so may cause the fan assembly to spring open
causing serious injury. (Do not loosen bolts (2)).

l Lift up on the grill to open the radiator grill to the fully open
position. Be sure the lock is applied when the grill is fully opened
before releasing the grill.

Be sure rear grill is locked in place before placing any part of

your body under this grill. Failure to do so may result in
serious injury.

l Closing radiator grill.

l The lock must be released before radiator grill can be closed.

Attempting to close the grill without releasing the lock will break
radiator grill.
l When closing the radiator grill, push up on grill first, then push lock
release bar (2) in the direction of the arrow to release the lock, then
close the grill.
l After closing the grill reinstall the lower part of the grill.

3-4 D51EX/PX-22
 MAINTENANCE

Do not start engine when fan guard (4) is in the raised

position. If engine is started without fan guard (4) in place,
serious injury may result.

D51EX/PX-22 3-5
MAINTENANCE
LUBRICANTS, COOLANT AND FILTERS

OUTLINE OF SERVICE
Always use Komatsu genuine parts for replacement parts, grease or oil.
When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the old oil and
fill completely with the new oil. Always replace the filter at the same time. (There is no problem if the small amount of oil
remaining in the piping mixes with the new oil.)

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

OIL
l Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pressure), and it
deteriorates with use.
Use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual.
Even if the oil is not dirty, change the oil after the specified interval.
l Oil corresponds to blood in the human body, so be careful when handling it to prevent any impurities (water, metal
particles, dirt, etc.) from getting in.
The majority of problems with machines are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
l Never mix oils of different grades or brands.
l Add the specified amount of oil. Having too much oil or too little oil both cause problems.
l If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases, please
contact your Komatsu distributor.
l When changing the oil, replace the related filters. When replacing the engine oil filter, fill the new filter with fresh, clean
specified oil before installing.
l We recommend periodic analysis of the oil to check the condition of the machine. For those who wish to use this service,
please contact your Komatsu distributor.

FUEL
l To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after
completing the day's work.
l The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
l Be extremely careful not to let impurities get in when storing or adding fuel.
l Always use the fuel specified in the Operation and Maintenance Manual.
l Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15oC (5 oF). It is
necessary to use the fuel that is suitable for the temperature.
l Before starting the engine, or when ten minutes have passed after adding fuel, drain the sediment and water from the fuel
tank.
l If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit. See
“REPLACE PRE AND MAIN FUEL FILTER CARTRIDGES” on page 3-61
l If there is any foreign material in the fuel tank, wash the tank and fuel system.
Remark
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this
machine uses an electronically controlled high-pressure fuel injection device. This device requires high

3-6 D51EX/PX-22
 MAINTENANCE
precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop
markedly.
COOLING SYSTEM COOLANT
l The coolant has the important function of preventing corrosion as well as preventing freezing.
l Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has an excel-
lent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine Supercoolant (AF-NAC). If
you use another coolant, it may cause serious problems such as corrosion of the engine and parts of the cooling system
that uses light metal such as aluminum.
l When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. For details, see “CLEAN
INSIDE OF COOLING SYSTEM (PAGE 3-26)”.
l When diluting the antifreeze coolant, use distilled water or (soft water).
l Natural water, such as a river water or well water (hard water), contains large amounts of minerals (calcium, magnesium,
etc.), and this makes it easier for scale to form inside the engine or radiator. Once scale is deposited inside the engine or
radiator, it is extremely difficult to remove. It also causes overheating due to poor heat exchange, so when you dilute the
coolant, we recommend that you use water with an overall hardness of less than 100 PPM.
l When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
l Antifreeze coolant is flammable, so be sure to keep it away from flame.
l For details of the ratio when mixing, see “CLEAN COOLING SYSTEM” on page 3-27. If the engine overheats, wait for
the engine to cool before adding coolant.
Even in areas where it is not necessary to prevent freezing, use Supercoolant (AF-NAC) at a mixing ratio of at least 30%
to prevent corrosion of the cooling system.
Supercoolant (AF-NAC) may be supplied in premix. In this case, never add diluting water.
l If the engine overheats, wait for the engine to cool before adding coolant.
l If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air entering the
coolant.

GREASE
l Grease is used to prevent binding and noise at the joints.
l The nipples not included in the MAINTENANCE section are nipples used when overhauling, so they do not need to be
greased periodically.
l If any part becomes stiff or generates noise after being used for a long time, grease it.
l Wipe off all of the old grease that is pushed out when greasing.
l Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of
the rotating parts.

CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)

KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is
periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other abnormalities.
Periodic use of KOWA makes the following possible:
l It enables abnormalities to be detected early, leading to reduction of repair costs and machine downtime.
l It enables repair schedules to be planned, leading to improved machine availability.

D51EX/PX-22 3-7
MAINTENANCE
KOWA ANALYSIS ITEMS
l Analysis of metal wear particles.
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of metal wear particles in the oil.

l Measurement of particle quantity.

This uses a PQI (Particle Quantifier Index) measurer to measure the
quantity of large iron particles in the oil.
l Others.
Measurements are made of items such as the ratio of water or fuel
in the oil, and the dynamic viscosity.
OIL SAMPLING
l Sampling interval.
250 hours: Engine.
500 hours: Other components.
l Precautions when sampling.
l Make sure that the oil is well mixed before sampling.
l Take samples regularly at regular intervals.
l Do not take oil samples on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.
OIL AND FUEL STORAGE
l Keep indoors to prevent any water, dirt, or other impurities from getting in.
l When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the side. (To
prevent moisture from being sucked in).
If drum cans have to be stored outside, cover them with a waterproof tarp or canvas, or take other measures to protect
them.
l To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use the oldest
oil or fuel first).

FILTERS
l Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering important
equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel (sulfur
content) being used.
l Never try to clean the filters (cartridge type) and use them again. Replace with new filters.
l When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please
contact your Komatsu distributor.
l Do not open packs of spare filters until just before they are to be used.
l Use Komatsu genuine filters.

3-8 D51EX/PX-22
 MAINTENANCE
ELECTRIC SYSTEM MAINTENANCE
l It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This will
cause electrical leakage and may lead to malfunction of the machine. Do not wash the inside of the operator's cab with
water. When washing the machine, be careful not to let water get into the electrical components.
l Minimum service relating to the electric system is a check of fan belt tension, check of damage or wear in the fan belt and
check of battery fluid level.
l Never install any electric components other than those specified by Komatsu.
l External electrical interference may cause malfunction of the control system controller. Before installing a radio receiver
or other wireless equipment, please contact your Komatsu distributor.
l When working at the seashore, carefully clean the electric system to prevent corrosion.
l When installing an operator's cab cooler or any other electrical equipment, connect it to an independent power source
connector. The optional power source must never be connected to the fuse, ignition switch, or battery relay.

HANDLING HYDRAULIC SYSTEM

l During and after operations, the hydraulic system is at high temperature. During operations, it is also under high pressure,
so pay careful attention to the following when carrying out inspection and maintenance of the hydraulic system.
l Stop the machine on level ground, lower the blade to the ground, and set it so that there is no pressure on the cylinder
circuit.
l Stop the engine.
l Immediately after operations, the hydraulic oil and lubricating oil are under pressure and at high temperature, so wait for
the temperature to cool before starting maintenance.
l Even when the temperature cools, there may still be internal pressure. When loosening plugs, screws, or hose connections,
do not stand directly in front. Loosen them gradually to release any internal pressure before removing.
l When carrying out inspection or maintenance of the hydraulic circuits, bleed the air to release the internal pressure.
l Minimal inspection or maintenance consists of checking the hydraulic oil level, replacing the filters, and changing the
hydraulic oil.
l When removing high-pressure hoses, check to be sure the O-ring is not damaged. If it is damaged, replace it.

D51EX/PX-22 3-9
MAINTENANCE
WEAR PARTS LIST
Wear parts such as the filter element, cutting edge, etc. are to be replaced at the time of periodic maintenance or before their
abrasion limits.
The wear parts should be changed as scheduled in order to use the machine economically.
For part change, Komatsu genuine parts should be used (excellent quality).
When ordering parts, please check the part number in the parts book and write them in the table below.
The parts in parentheses are to be replaced at the same time.

Item Part Name Qty Replacement frequency

Fuel pre-filter Cartridge (incl. O-ring) 1 Every 500 hours

Engine oil filter Cartridge 1 Every 500 hours
Hydraulic oil filter Cartridge 1 Every 2000 hours
HST charge filter Cartridge 1 Every 2000 hours
Hydraulic cap vent Element 1 Every 2000 hours
Air conditioner
Filter 1 Every one year
RECIRC filter
Air conditioner
Filter 1 Every one year
FRESH filter
Air cleaner Element assembly 1 —
Fuel filter (main) Cartridge 1 Every 1000 hours
Belt (with A/C) — 1 —
Belt (without A/C) — 1 —
Wide blade cutting edge
— 56 When necessary
(25 bolts) (25 nuts)
Narrow blade cutting edge
— 52 When necessary
(23 bolts) (23 nuts)

3-10 D51EX/PX-22
 MAINTENANCE
RECOMMENDED FUEL, COOLANT, AND LUBRICANT
l Komatsu genuine oil is the most suitable oil for Komatsu construction equipment. It complies with higher standards than
usual in order to improve the reliability and durability of the construction equipment. In order for you to maintain your
machine for long periods in the best condition, we recommend use of the Komatsu oils, grease, and coolant listed in this
Operation and Maintenance Manual.
l If the recommended oils are not used, excess wear and a drop in the service life of the engine, power train, and cooling
system may occur.
l Commercially available oil additives may lower the performance of the oil. Komatsu does not recommend the use of any
commercially available oil additive.
l Please select the oil to match the ambient temperature as shown in the table.
l The Specified Capacity is the total amount of oil, including oil for the components and oil in the piping. The Refill Capac-
ity is the amount of oil needed to refill the system when changing the oil during inspection and maintenance.
l When starting the engine in ambient temperatures of lower than 0°C, even though the ambient temperature goes up to
10°C more or less in the daytime, do not use SAE30DH. Use another multigrade oil in the table.

Adjusted fuel service interval due to sulfur content

Fuel sulfur content Engine oil change interval

0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval

D51EX/PX-22 3-11
MAINTENANCE
Ambient Temperature Recommended
Fluid
Reservoir -22 -4 14 32 50 68 86 140 122°F Komatsu
Type
-30 -20 -10 0 10 20 30 40 50°C Fluids
Komatsu
SAE 0W30EOS and HTHS 3.5min. (Note 1) EOS0W30
Komatsu
SAE 5W40EOS and HTHS 3.5min. (Note 1) EOS5W40
Engine oil pan

Engine oil

Komatsu
SAE 10W30DH EO10W30DH
Komatsu
SAE 15W40DH EO15W40DH

SAE 30DH Komatsu EO30DH

Power
Final drive case train oil TO 30 (SEA30) TO30
(Note 2)

Idler Engine SAE 30 EO30DH

oil

Hydraulic
oil TOS5W30 (SEA5W30)
(synthetic TOS5W30
type oil)

Power
train TO 10 TO10
oil
Hydraulic system

SAE10W30DH EO10W30DH
Engine
oil
SAE15W40DH EO15W40DH
SAE10WDH EO10DH

Hyper GO-T (NLGI NO. 0) GO-T

white grease
(Note 4) G2-T (NLGI NO. 2) G2-T

Moly disul.
LM-G (NLGI NO. 2) LM-G
grease

Grease
LM-G (NLGI NO. 2) GO-L1
Lithium LM-G (NLGI NO. 2) G2-L1
grease
LM-G (NLGI NO. 2) G2-L1-S

Bio grease G2-BT (NLGI NO.2) G2-BT

Engine Cooling Super

AF-NAC (Note 5) AF-NAC
system coolant

No.2-D ASTM N0. 2-D

Fuel tank Diesel fuel
No. 1-D ASTM No. 1-D

3-12 D51EX/PX-22
 MAINTENANCE
Final drive Hydraulic Idler Fuel Cooling
Engine oil pan
case (each) system (each) tank system
Specified liter 23 6.0 123 0.21 270 35
capacity US gal 6.08 1.58 32.5 0.056 71.3 9.25
Refill liter 20 5.5 63 0.21 ⎯ ⎯
capacity US gal 5.28 1.45 16.64 0.056 ⎯ ⎯

H Always Use Diesel Oil For The Fuel. See (“FILL PROCEDURE page 3 - 54”).
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses
an electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication,
so if low viscosity fuel with low lubricating ability is used, the durability may drop markedly.

l Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS (High-Temperature High-Shear Viscosity
150°C) must be equal to or higher than 3.5 mPa-S. As these are special oils and are not Komatsu genuine oils, as a basic
rule, we do not recommend SAE0W30EOS and SAE5W40EOS.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
l Note 3:For operations in or by rivers, lakes seashores or any large body of water. In areas protected by environmental laws
we recommend biodegradable oils. Consult with your Komatsu distributor.
Note 4: Hyper white grease (G2-TE) is a high performance white grease.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings,
the use of G2-TE is recommended.
Load Friction Heat Water Biodegrade
Type of grease Remarks
performance resistance resistance resistance ability
Hyper white grease s s s s w Non-black high load
Moly. disul. grease l s l l w Molybdenum grease
Lithium grease m l l l w ⎯
Biodegradable grease m s l s Synthetic grease
s: Excellent l: Good m: Normal w: Poor

l Note 5: Super Coolant

(1) Super coolant has the important function of preventing corrosion in the cooling system as well as the function of
preventing freeze-up’s. As a general rule, we do not recommend use of any coolant other than the Komatsu genuine super
coolant (AF-NAC). If any other coolant is used, it may cause serious problems with the engine cooling system.
(2) For details on mixing ratio of coolant to water see “CLEAN COOLING SYSTEM” on page 3-27. When the machine
is shipped from the factory, it is filled with coolant containing 30% or more of Komatsu genuine super coolant AF-NAC,
unless otherwise stated. In this case, there is no particular need for adjustment of the density for temperatures down to -
10oC (14oF). If the temperature goes below this, adjust the density of the super coolant.
(3) To maintain the corrosion resistance power of the coolant, keep the density above 30%.

RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS

When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications, refer to
the Komatsu web page or consult your Komatsu distributor.

D51EX/PX-22 3-13
MAINTENANCE
LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS

No. Supplier Engine Oil [CD or CE] Gear Oil Grease Antifreeze Coolant
SAE10W, 30, 40 [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil Permanent Type
marked * is CE.)
1 KOMATSU EO10-CD GO90 G2-LI AF-ACL
EO30-CD GO140 G2-LI-S AF-PTL
EO10-30CD AF-PT (Winter,
EO15-40CD one-season type)
2 AGIP Diesel sigma S Rotra MP GR MU/EP -
super diesel
multigrade
*Sigma turbo
3 AMOCO *Amoco 300 Multi-purpose gear oil PYKON premium grease -
4 ARCO *Arcofleet S3 pius Arco HD gear oil Litholine HEP 2 -
Arco EP moly D
5 BP Vanellus C3 Gear oil EP Energrease LS-EP2 Antifreeze
Hypogear EP
6 CALTEX *RPM delo 400 Universal thuban Marfak all purpose 2 AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
7 CASTROL *Turbomax EP MS3 Antifreeze
*RX super EPX Spheerol EPL2
CRD Hypoy
Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -
9 CONOCO *Fleet motor oil Universal gear lubricant Super-sta grease -
10 ELF Multiperformance 3C - Tranself EP Glacelf
Performance 3C Tranself EP type 2
11 EXXON Essolube D3 Gear oil GP Beacon EP2 All-season coolant
(ESSO) *Essolube XD-3 Gear oil GX
*Essolube XD-3 Extra
*Esso heavy duty
Exxon heavy duty
12 GULF Super duty motor oil Multi-purpose gear lubri- Gulfcrown EP2 Antifeeze and coolant
*Super duty plus cant Gulfcrown EP special
13 MOBIL Delvac 1300 Mobilube GX Mobilux EP2 -
*Delvac super Mobilube HD Mobilgease 77
10W-30, 15W-40 Mobilgrease special
14 PENNZOIL *Supreme duty Multi-purpose 4092 Multi-purpose white grease Antifreeze and
fleet motor oil Multi-purpose 4140 705 summer coolant
707L White-bearing grease
15 PETRO- FINA kappa TD FINA potonic N FINA marson EPL2 FINA tamidor
FINE FINA potonic NE
16 SHELL Rimura X Spirax EP Albania EP grease -
Spirax heavy duty
17 SUN - Sunoco GL5 Sunoco ultra prestige 2EP Sunoco antifreeze
gear oil Sun prestige 742 and summer coolant

3-14 D51EX/PX-22
 MAINTENANCE
No. Supplier Engine Oil [CD or CE] Gear Oil Grease Antifreeze Coolant
SAE10W, 30, 40 [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil Permanent Type
marked * is CE.)
18 TEXACO *Ursa super plus Multigear Multifak EP2 Coda 2055 startex
Ursa premium Starplex 2 antifreeze coolant
19 TOTAL Rubia S Total EP Multis EP2 Antigel/antifreeze
*Rubia X Total Transmission
TM
20 UNION *Guardol MP gear lube LS Unoba EP -
21 VEEDOL *Turbostar Multigear - Antifreeze
*Diesel star Multigear B
MDC Multigear C

D51EX/PX-22 3-15
MAINTENANCE
TIGHTENING TORQUE SPECIFICATIONS

If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to
the tightened parts, and this will cause failure of the machine or problems with operation.
Pay careful attention when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
The tightening torque is determined by the width across the flats of the nut and bolt.
If it is necessary to replace any nut or bolt, use a Komatsu genuine part
of the same size as the part that was replaced

Width Tightening torque

Thread
across
diameter Target value Service limit
flat
a(mm)
b(mm) N•m lbft N•m lbft

6 10 13.2 9.8 11.8 - 14.7 8.7 - 10.8

8 13 31 23.1 27 - 34 20.3 - 25.3

10 17 66 48.5 59 - 74 43.4 - 54.2

12 19 11 83.2 98 - 123 72.3 - 90.4

14 22 177 130.2 157 - 196 115.7 - 144.7

16 24 279 206.1 245 - 309 180.8 - 227.8

18 27 382 282.1 343 - 425 253.2 - 314.6

20 30 549 405.0 490 - 608 361.7 - 448.4

22 32 745 549.7 662 - 829 488.2 - 611.2

24 36 927 683.5 824 - 1030 607.6 - 759.5

27 41 1320 976.5 1180 - 1470 868.0 - 1085.0

30 46 1720 1265.8 1520 - 1910 1121.1 - 1410.4

33 50 2210 1627.4 1960 - 2450 1446.6 - 1808.3

36 55 2750 2025.2 2450 - 3040 1808.3 - 2242.2

39 60 3280 2423.1 2890 - 3630 2133.7 - 2676.2

H Apply the following table for Hydraulic Hose.

Width Tightening torque

Thread
across
diameter Target value Service limit
flat
a(mm)
b(mm) N•m lbft N•m lbft

9/16-18UNF 19 44 32.5 35 - 63 25.3 - 47.0

11/16-16UN 22 74 54.2 54 - 93 39.8 - 68.7

13/16-16UN 27 103 75.9 84 - 132 61.5 - 97.6

1-14UNS 32 157 115.7 128 - 186 94.0 - 137.4

13/16-12UN 36 216 159.1 177 - 245 130 - 180.8

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

3-16 D51EX/PX-22
 MAINTENANCE
To ensure safety at all times, the machine must have periodic maintenance. To further improve safety, the parts listed in the
table below should be replaced on a consistent basis. These parts are closely related to safety and fire prevention.
The material of these parts changes as time passes, or they easily wear or deteriorate. Because it is difficult to judge the
condition of the parts simply by periodic inspection, they should be replaced after a specified period of time regardless of their
appearance. This is necessary to ensure that they maintain their function completely.
However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced
immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time as the hoses.
When replacing the hoses, replace the O-rings, gaskets, and other such parts at the same time.
Ask your Komatsu distributor to replace the safety critical parts.

SAFETY RELATED CRITICAL PARTS

No. Safety critical parts for periodic replacement Qty Replacement interval

1 Fuel hose frame junction (water separator) 2

2 Fuel hose (water separator - fuel feed pump) 1
3 Fuel return hose (fuel drain connection) 1
4 Engine fuel drain assembly 1
5 Case, plug and O-ring of water separator 1
6 Turbocharger lubrication hose 1
7 Hose (PPC circuit) hydraulic tank (center portion under floor) 1
Hose (5-spool solenoid valve, right side under floor - block (HST pump under
8 1
floor)
Hose (LH travel motor brake port bulk head - RH travel motor brake port Every two years or
9 1
bulkhead) 4000 hours,
whichever comes
10 Hose (bulkhead - solenoid valve) 1
sooner
11 Hose (towing valve - parking brake control valve) 1
12 Hose (LH travel motor FORWARD port MB - HST pump (PA1) 1
13 Hose (LH travel motor BACKWARD port MA - HST pump (PB1) 1
14 Hose (RH travel motor FORWARD port MA - HST pump (PA2) 1
15 Hose (RH travel motor BACKWARD port MB - HST pump (PB2) 1
16 Suction hose (hydraulic tank - charge pump HSS pump) 2
17 Suction hose (delivery for hydraulic tank - hydraulic pump) 2
18 Hose (hydraulic pump - main control valve) 1
19-1 Accumulator (for control circuit) 1
20 Seat belt 1 Every three years

D51EX/PX-22 3-17
MAINTENANCE
MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
MAINTENANCE WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CHECK ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ENGINE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
CLEAN COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
TRACK SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
REVERSING OR REPLACING END BITS AND CUTTING EDGES . . . . . . . . . . . . . . . . . . . 3-35
ADJUST PLAY IN CENTER BALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
DOOR HINGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
CHECKING WINDOW WASHER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
CHECKING AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
REPLACE WIPER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
RELEASING INTERNAL PRESSURE ON HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 3-41
BLEEDING AIR FROM HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
CLEAN, CHECK RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
EVERY 50 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
DRAINING SEDIMENT FROM FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
EVERY 250 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
CHECK OIL LEVEL IN FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
LUBRICATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
CHECK LEVEL OF BATTERY ELECTROLYTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
CHECK BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) . . . . . . . . . . . . . . . . . . . . . . . . 3-53
EVERY 500 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
REPLACE FUEL PRE-FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
EVERY 1000 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
CHANGE OIL IN FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
CHECK ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS . . . . . . . . . . . 3-59
CHECK FOR LOOSE ROPS MOUNT BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
REPLACE PRE AND MAIN FUEL FILTER CARTRIDGES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
EVERY 2000 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE . . . . . . . . . . 3-63
CHECK ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
CHECK ENGINE VALVE CLEARANCE, ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
REPLACE HYDRAULIC TANK BREATHER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
CHECKING CHARGE PRESSURE ACCUMULATOR (CONTROL CIRCUIT) . . . . . . . . . . . 3-67
EVERY 4000 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
CHECK WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
CHECK VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
CHECK STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

3-18 D51EX/PX-22
 MAINTENANCE
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
CHECKING FOR MISSING FUEL SPRAY CAP, HARDENING OF RUBBER . . . . . . . . . . . 3-70

D51EX/PX-22 3-19
MAINTENANCE
MAINTENANCE WHEN REQUIRED

CLEANING THE MACHINE

CLEAN TIPS
Never use flammable liquids to clean your machine. Use only
approved non-flammable cleaning solvents to clean parts or the
machine itself. Avoid using high pressure steam cleaners or caustic
soaps to wash the machine if possible. Steam cleaning or using caustic
soaps may damage paint, wiring or sensitive electrical components.

Never use high pressure water or flood the inside of the operator’s
cab. Doing so may damage sensitive electrical components.

When pressure washing, use high pressure hot water and mild grease
cutting soaps.

CLEANING THROUGH ACCESS AREAS

Before proceeding with any cleaning procedures, open the following access areas.
1. Remove undercarriage cover plate (a) at the front of the machine.

2. Remove all undercarriage cover plates (b) at the center and rear of
the machine.

3-20 D51EX/PX-22
 MAINTENANCE
3. Engine right side cover and grill.
A. Remove six bolts and remove the two right engine side
covers (1).

Remove four bolts and open the front grill (2).

Do not operate the work equipment with the engine service

doors in the open position, damage to the service doors or
hood may result.

B. Open right rear cover (3) to expose hydraulic valves.

4. Open three left side covers on the engine hood (4) and on the bat-
tery and hydraulic tank (5).

Do not operate the work equipment with the engine service

door (4) in the open position, damage to the engine service
door or hood may result.

D51EX/PX-22 3-21
MAINTENANCE
5. Remove floor mat and floor cover plate.

Remark
Be careful not to allow cleaning solvent or water to get on the
instruments or bezel areas of the machine. If necessary,
cover all electrical components around the interior of the cab.

l Remove rear radiator bottom four bolts (6). Remove lower radiator
grill.

Do not separate the grill assembly from the fan assembly.

Doing so may cause the fan assembly to spring open
causing injury.

6. Open top radiator grill until the top latch holds grill assembly in
place.

Remark
Be careful when cleaning radiator core, high pressure may
damage radiator fins.

Be sure rear grill is locked in place before placing any part of

your body under this grill. Failure to do so may result in
severe injury.

If you must remove the fan guard, do not start the engine
with fan guard removed, serious injury may result.

If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine
and the engine will suffer damage. Always stop the engine before performing these operations.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use safety glasses, dust mask, and other protective equipment.

7. After cleaning machine, lubricate or grease all required pivot points on the machine.

3-22 D51EX/PX-22
 MAINTENANCE
CHECK ELECTRICAL INTAKE AIR HEATER
Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater
repaired or checked for dirt or disconnections.

ENGINE AIR FILTER

If inspection, cleaning, or maintenance is done with the engine running, dirt will enter the engine and
cause damage to the engine. Stop the engine before carrying out these operations.
Flying dirt could cause personal injury when using compressed air. Wear protective glasses, dust mask, or
other protective equipment.

If air cleaner clogging caution lamp on the machine monitor lights up,
clean the air cleaner element.
Remark
Do not clean the element until the air cleaner clogging
caution lamp lights up. If the element is cleaned frequently
before the air cleaner clogging caution lamp lights up, the air
cleaner will not be able to display its performance fully and
the cleaning efficiency will drop. In addition, the frequency of
dirt stuck to the element falling inside the inner element will
increase.

CLEANING OR REPLACING OUTER ELEMENT

1. Open engine side cover on the left side of machine.

2. Unlock the stopper (1), then remove dust cap (2) by turning
counter-clockwise.

3. Remove outer element (4) by rocking it lightly up and down and

rotating the element to the left and right to pull it out.
4. Do not remove the inner element (5) when doing this procedure.

Remark
Never remove inner element (5). If it is removed, dust will enter
and cause engine trouble.
5. When the outer element (4) has been removed, check the inner
element (5) to be sure it has not come out of position and is not at
an angle. If the element is at an angle, push it straight in until it is
firmly in place.

D51EX/PX-22 3-23
MAINTENANCE
6. Clean the inside of the air cleaner body and dust cap.

Remark
When cleaning the dust cap, do not remove evacuator valve
(3).

7. Direct dry compressed air less than 7 kgf/cm (99.4 PSI) to the
outer element from inside along its folds, then direct it from
outside along its folds and again from inside.
Remark
When cleaning the element, do not hit or beat it against
anything.
Do not use an element whose folds, gasket or seal are
damaged.

A. Replace the outer element which has been cleaned six times
repeatedly or used throughout a year. Replace the inner
element at the same time.

B. Replace both inner and outer elements when the caution

lights up soon after installing the cleaned outer element even
though it has not been cleaned six times.

8. If small holes or thinner parts are found on the element when it is

checked by shining a light through it after cleaning, replace the
element.
8. Install the cleaned outer element (4) and install dust cap (2), then
secure them by turning it clockwise.
l When installing the dust cap, be sure the arrow on the cap is
pointing downward.

3-24 D51EX/PX-22
 MAINTENANCE
l Each time the element is cleaned, remove one tab from the
service record decal (7).
9. Close the left engine side cover.

REPLACING INNER ELEMENT

1. Open the engine side cover on the left side of the machine.
2. Unlock the stopper (1) then remove the dust cap (2) by turning it
in a counter-clockwise direction.
3. Hold the outer element (4), rock it lightly up and down and to the
left and right, and rotate the element to the left and right to pull it
out.

4. Do not remove inner element (5) when doing this.

5. When the outer element (4) has been removed, check to be sure
the inner element has not come out of position and is not at an
angle. If is at an angle, insert your hand and push it in straight.

6. Clean the inside of the air cleaner body and dust cup.
Remark
When cleaning the dust cup, do not remove evacuator valve
(3).
7. Remove inner element (5), then install a new inner element
immediately.

D51EX/PX-22 3-25
MAINTENANCE
8. Install a new outer element (4) and install dust cap, then secure
them by turning clockwise.
l When installing the dust cup, be sure arrow points down.

l Each time the element is cleaned, remove one seal tab from
the service record decal (7).
9. Close the left engine side cover.

3-26 D51EX/PX-22
 MAINTENANCE
CLEAN COOLING SYSTEM

Immediately after the engine is stopped, the coolant is hot and the radiator is under high internal pressure.
If the cap is removed to drain the coolant in this condition, there is a danger of burns. Wait for the temper-
ature to cool, then turn the cap slowly to release the pressure before removing it.
When leaving the operator's seat, set the work equipment and parking brake lever in the LOCK position.
Never go under the machine while the engine is running.

H Stop the machine on level ground when cleaning or changing the coolant.
Clean inside of the cooling system, change the coolant according to the table below.
Interval for cleaning inside of cooling
Antifreeze coolant
system and changing antifreeze coolant
Komatsu super coolant Every two years or every 4000 hours,
(AF-NAC) whichever comes first

• The coolant has the important function of preventing corrosion as well as preventing freezing and overheating.
• Even in the areas where freezing is not an issue, the use of antifreeze is essential.
• Komatsu machines are supplied with Komatsu Super coolant (AF-NAC). Komatsu Super coolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours.
As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine supercoolant (AF-NAC).
If you use another coolant, it may cause serious problems such as corrosion of the engine and parts of the cooling system
that use light metal such as aluminum.
• When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table
see “MIXING RATE OF WATER TO ANTIFREEZE” on page 3-27.
• It is actually better to estimate the temperature about 10°C (50°F) lower when deciding the mixing ratio.
• The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/
total amount of coolant x 100).
Even in areas wher it is not necessary to prevent freezing, use the supercoolant (AF_NAC) at a mixing ratio of at least
30% to prevent corrosion of the cooling system.
The freezing temperature of undiluted antifreeze is -15ºC (5ºF). Do not store undiluted antifreeze at a temperature of
below -15ºC (5ºF).

MIXING RATE OF WATER TO ANTIFREEZE

.

Min. atmospheric °C -10 -15 -20 -25 -30

temperature °F 14 5 -4 -13 -22
Liters 17.5 17.5 17.5 17.5 17.5
Amount of antifreeze
US gal 4.62 4.62 4.62 4.62 4.62
Liters 17.5 17.5 17.5 17.5 17.5
Amount of distilled water
US gal 4.62 4.62 4.62 4.62 4.62
Ratio % 50 50 50 50 50

D51EX/PX-22 3-27
MAINTENANCE
FLUSHING THE COOLING SYSTEM
Due to the unique design of the cooling system on this machine the procedures outlined require the technician to flush the
radiator and engine block separately. Failure to follow the outlined procedures may not fully purge the cooling system of the
old coolant thus resulting in the contamination of the new coolant. If you are unsure of the outlined procedures, contact your
Komatsu distributor.
• Always use distilled or deionized water to mix with antifreeze for the cooling system.
• We recommend use of an antifreeze density gauge to control the mixing proportions.
• Prepare the following: Container should hold a minimum of 61 L (16.11 US gal) capacity to mix the coolant.
• Prepare a hose to supply the coolant mixture.
• Prepare a pressurized fresh water supply hose and the needed flushing equipment (obtain locally).

DRAINING COOLANT FROM SYSTEM

1. Remove the radiator cap (1) before starting flushing procedures.
Check the temperature of the coolant.
Remark
Before proceeding with a cooling system flush, be sure the
engine and it’s coolant are completely cooled down to room
temperatures. Never run the engine dry or during a flushing
procedure. Damage to the engine may result.
2. Push down on radiator cap (1) and turn counter clockwise until it
contacts the stopper, then remove it.
3. Remove the right side engine covers and open front grill to access
cooling system components.
4. Locate all drain points within the cooling system. Open drain
valves (2) and (3). Open vent plug (8) and precede to recover all
coolant in appropriate containers

Remark
It is in violation of EPA laws to drain engine coolant on the ground, in rivers or lakes or in a city or sewer
systems. All coolant must be captured and recycled according to EPA laws. Failure to do so may result in fines
or punishment.

3-28 D51EX/PX-22
 MAINTENANCE
5. Once the radiator and cooling lines are empty, remove the engine
water jacket plug (4) located on the right rear side of the engine
block and proceed to capture the remaining amount of coolant in
the engine water jacket.

FLUSHING RADIATOR CORE

1. After fully draining the coolant from the radiator and engine,
remove the lower radiator outlet hose (6).

2. Remove the three wire harness retaining clamps (b) and two line
clamps (a) (one clamp (a) is behind hood cowling).
l Pull line (5) out to access engine and radiator top outlet ports.
3. Using a fresh water pressurized hose flush the radiator inlet and
outlet (5) and (6) switching water flow simultaneously to
thoroughly flush the radiator core.
l Continue with this procedure until all water flow from radiator
core is clear in both directions and free of any sediment.
l Occasionally remove and reinstall radiator cap to help loosen
sediment within the radiator core.

HEATER CORE
1. Remove feet heater hose (9) at heater core inlet. It is not necessary
to remove heater core outlet hose (10).
2. Flush heater core through feet heater core inlet (9) and lower
radiator hose outlet (6).
l Turn ignition switch to the “ON” position and set the
temperature control to full heat “H” position.
3. Using a fresh water pressurized hose flush the heater core inlet and
outlet switching water flow simultaneously to thoroughly flush the
heater core.
l Continue with this procedure until all water flow from heater
core is clear in both directions and free of any sediment.

D51EX/PX-22 3-29
MAINTENANCE
FLUSHING ENGINE BLOCK
1. Once the radiator and heater core has been flushed, proceed with
flushing the engine block through heater hose (9), engine block
drain (4) and water pump outlet (6) switching water flow
simultaneously between the three to thoroughly flush the engine
block.
l Continue with this procedure until all water flow from engine
block is clear in all directions and free of any sediment.
l If the system needs further cleaning it is recommenced to use
cleaning agent (FLEETRITE Restore CC261 or Restore
Plus CC2638). Follow cleaning agent instructions.

2. Once flushing procedures are completed, close both valves (2) and
(3).
3. Reinstall all lines (5), (6), (9) and (10) and clamp in place using
clamp (a).
4. Reinstall engine block plug (4).

Remark
Leave vent valve (8) open while filling cooling system, this will
vent any trapped air during fill procedures. Close valve after
filling system.
5. Pour the coolant/water mixture into the filler port (1). See “MIX-
ING RATE OF WATER TO ANTIFREEZE” on page 3-27 for the
mixing rate of coolant and water.
6. To bleed air in the cooling system, run the engine for ten minutes at low idle, until temperature reaches 90oC (194oF) then
for another ten minutes at high idle. When doing this step, leave the radiator cap off.
7. Check system for leaks.
8. Drain the coolant from sub-tank (1), clean the inside of sub-tank,
then add coolant mixture until the coolant level is between the
FULL and LOW marks.

Remark
If Super coolant will not be used in the cooling system it is
important to be sure all parts of the cooling system do not
have any traces of Super coolant left in the system. Be sure
to thoroughly flush the cooling system before adding the new
coolant to the system. Failure to do so may damage the
cooling system.

9. Stop the engine, wait for approximately 30 minutes, then add

coolant mixture until the coolant level is near the coolant filler port
(1), and tighten the cap. Check the coolant level and add coolant
mixture, if necessary.

Remark
When mixing coolant with water, use distilled or deionized
water only. Failure to do so may clog the cooling system.

3-30 D51EX/PX-22
 MAINTENANCE
TRACK SYSTEM MAINTENANCE

The wear of pins and bushings on the undercarriage will vary with the working conditions and types of soil. It is thus necessary
to continually inspect the track tension so as to maintain the standard tension. Carry out the check and adjustment under the
same conditions as when operating (on jobsites where the track becomes clogged with mud, measure with the track clogged
with mud).
CHECK AND TIGHTEN TRACK SHOE BOLTS
If the machine is used with loose track shoe bolts (1), they will break, so
tighten any loose bolts immediately.

TIGHTENING TRACK SHOE BOLTS

1. First tighten to a torque of 196 ± 20 Nm (144 ± 15 ft/lbs) then check
to be sure the nut and shoe are in close contact with the link
contact surface.
2. After checking, tighten further 120º ± 10º.

ORDER FOR TIGHTENING

Tighten the bolts in the order shown in the diagram on the right. After
tightening, check to be sure the nut and shoe are in close contact with
the link mating surface.

CHECKING AND ADJUSTING TRACK TENSION

INSPECTION
Stop the machine on level ground (stop with the transmission in
FORWARD without applying the brake). Then place a straight bar on
the track shoes between the carrier roller and the idler as shown in the
figure, and measure the clearance between the bar and the grouser at the
midpoint.

If the clearance (a) is 20 to 30 mm (0.79 to 1.18 in), the

tension is standard. If the track tension is not at the standard value,
adjust it in the following manner.

D51EX/PX-22 3-31
MAINTENANCE
ADJUSTMENT
INCREASING TRACK TENSION
1. Remove cover (4) and prepare a grease pump.

l There is danger of plug (1) flying out under the high

internal pressure of the grease. Never loosen plug (1)
more than one turn.

l Never loosen any part other than plug (1). Never put
your face in the mounting direction of plug (1).

l If the track tension cannot be loosened with the

procedure given here, please contact your Komatsu
distributor.

2. Pump in grease through grease fitting (2) with a grease pump.

(Grease fitting (2) forms one part with plug (1).

3. To check if the tension is correct, run the engine at low idle, move
the machine slowly forward (by an amount equal to the length of
track on ground), then stop the machine without using the brakes.
4. Check the track tension again, and if the tension is not correct,
adjust it again.

5. Continue to pump in grease to get the correct clearance under the

straight edge. If the tension is still loose, the pin and bushing are
excessively worn, so they must be either turned or replaced.
Contact your Komatsu distributor for repairs.

Remark
It is possible to extend the idler until the dimension “S”
becomes 20 mm (1.0 in) or less.

3-32 D51EX/PX-22
 MAINTENANCE
LOOSENING TRACK TENSION

It is extremely dangerous to release the grease by any method except the procedure given below.
If the track tension is not relieved by this procedure, please contact your Komatsu distributor for repairs.

A. Loosen plug (1) gradually to release the grease.

B. Turn plug (1) a maximum of one turn.

C. If the grease does not come out smoothly, move the machine
forwards and backwards a short distance.

D. Tighten plug (1).

E. To check if the tension is correct, run the engine at low idle,

move the machine slowly forward (by an amount equal to the
length of track on ground), then stop the machine.

F. Check the track tension again, and if the tension is not correct,
adjust it.

IDLER GUIDE ADJUSTMENT

Since the idlers are forced to move forward and backward by an external force guide plates will be worn out. Wear of these
plates will cause the vibration of idlers from side to side or inclination of the idlers, and running off of track links from the
idlers or unevenly worn idler and links may result. Therefore, adjust the idlers according to the following procedure.
SIDE ADJUSTMENT
Move the machine by 1 to 2 m (3.3 to 6.6 ft) on a level place, then
measure clearance (a) between the track frame and guide plate (at four
places of both sides, inside, and outside).

If the clearance (a) exceeds 4.0 mm (0.16 in), loosen bolts (1), and pull
out the shim to adjust the clearance at one end to 0.5 to 1.0 mm (0.02 to
0.04 in).
l Thickness of one shim is: 1.0 mm (0.04 in).

D51EX/PX-22 3-33
MAINTENANCE
VERTICAL ADJUSTMENT

1. To determine the amount of adjustment, measure clearance “b” then subtract 2 mm and record the results (amount of
adjustment).
l Example:
If clearance C = 5mm (0.197 in)
Amount of adjustment = 5 - 2 = 3 mm (0.118 in)
2. Loosen bolts (1) three turns.

Remark
When doing this do not loosen bolts more than three turns. Also, do not replace the bolts with longer or shorter
bolts.
3. Remove bolts (9) and then remove cover (10).
4. Move shims (t = 1 mm) from the upper side (7) to the lower side (8). The amount of shims to move should be equal to the
amount of adjustment found in step 1.
l Example:
If amount of adjustment is found to be 3 mm as above, move three shims from upper side to lower side.

Remark
The total number of shims must not be changed.
5. Replace cover (10) and bolts (9). Tighten bolts (1)
6. Check clearance “b”. Should be 2mm.

3-34 D51EX/PX-22
 MAINTENANCE

REVERSING OR REPLACING END BITS AND CUTTING EDGES

It is dangerous if the work equipment moves during the turning or replacement operation.
Set the work equipment in a stable condition, set the work equipment lock lever to the LOCK position, then
stop the engine.

Flip or replace the end bits and cutting edges before it is worn out to the
Point that the blade is being worn.
1. Raise the blade to a proper height, position a block under the frame
to prevent the blade from falling.
2. Set the work equipment lock lever to the LOCK position.
3. Measure the wear of the end bit and cutting edge in accordance
with the wear standards given below.
Item Judgement standard
mm (in) mm (in)
No. Measurement point
New condition Replace
1 Height of end bit 102 (4) 85 (3.3)
2 Height of cutting edge 102 (4) 85 (3.3)

Remark
If the cutting edge and the end bit on both sides are worn out,
replace with new ones.
If it has been worn out up to the point of damaging the blade,
repair the blade surface and then reverse or replace.
4. Remove the cutting edge and the end bit and clean the mounting
surface.
5. Flip or replace the cutting edge and the end bit when worn out.
A. Remove nut (1) and bolt (2), then replace or flip the cutting
edges and the end bits.

B. Install the cutting edge on the blade and tighten the bolts temporarily. Press the blade against the ground to eliminate
the play of bolt (2), then tighten the bolt to the specified torque.

l Tightening torque of mounting nut: 255 ± 34.3 Nm (188.1 ± 25.3 lbft)

l If bolt (2) and nut (1) are damaged, replace them with new ones at the same time.
6. After several hours of running, re-torque the nuts.

D51EX/PX-22 3-35
MAINTENANCE

ADJUST PLAY IN CENTER BALL

When adjusting, always set the work equipment lock lever to the LOCK position except when operating the
blade.

When the blade assembly has been removed for transportation, the play of the center ball must be adjusted when assembling it
again. If this is not done, soil will enter and cause premature wear or damage of the ball and vibration of the work equipment,
so adjust as follows.
Remove bolts (1) and cap (2), then remove shims (3).
With shims (3) removed, install cap (2) and tighten with bolts (1).
With bolts pulled up to eliminate rattling and clearance (A) evenly all
around.
Measure clearance (A), then add 0.2 to 0.7mm (0.008 to 0.028 in) to
calculate the shim thickness. Assemble this shim thickness.
l Standard shim thickness: (A) 6 - 8 mm (0.2 - 0.3 in).
l Thickness of shim: 0.5 mm (0.02 in) 1.0 mm (0.04 in).
l Tightening torque: 456 - 569 Nm (336.3 - 419.5 ft/lbs).
l For pitch rod shim thickness: 0.5 - 1.0 and 2.0mm.

ADJUST PLAY IN CENTER BALL

l Adjustment is in similar way.
l Adjust play in pitch rod (1) as well as center ball (2).
l Standard shim thickness:6 - 8 mm (0.2 - 0.3 in).
l Thickness of shim:0.5 mm (0.02 in) 1.0 mm (0.04 in) 2.0 mm (0,08 in).
l Tightening torque:823-1029 Nm (607 - 759 ft/lbs)

3-36 D51EX/PX-22
 MAINTENANCE
DOOR HINGES
GREASE DOOR HINGE
If the hinge squeaks when the door is opened or closed, spray lubricant on the hinge
through the bushing slit (2).

CHECK DOOR LOCK STRIKER

If the wear of the door lock striker (1) exceeds 0.5 mm (0.02 in), replace
the striker. If it is used as it is, the play will increase and this may result
in breakage of the hinge or door lock. Loosen bolts (a) and adjust striker.

REPLACE DOOR DAMPER

If the depth of the door damper rubber groove is less than 2 mm (0.08
in), replace the damper.
There are four dampers each at the top and bottom on the left and right
doors.

CHECK DOOR LATCH

Hold the door open and check that there is still grease inside the latch.
If the amount of grease is low or there is no more grease, coat the inside
of the latch with grease from portion (2).
If there is no more grease inside the latch, the movement will become
poor because of dust inside the latch, and the handle may be stiff when
opening the door.

D51EX/PX-22 3-37
MAINTENANCE
CHECKING WINDOW WASHER FLUID LEVEL
If there is air in the window washer fluid, check the level of the fluid in window
washer tank (A) and (B). Add automobile window washer fluid if necessary.

When adding fluid, be careful not to let any dust get in.

Never use flammable fluids as window washer solvents.

MIXTURE RATIO OF PURE WASHER FLUID AND WATER

Since the ratio should be varied depending on ambient temperature, replenish washer fluid at the following mixture ratio,
taking temperature into account.

Operation area and season Mixture ratio Freezing temperature

Normal Pure washer fluid 1/3: water 2/3 - 10º C (14º F)

Winter in cold region Pure washer fluid 1/2: water 1/2 - 20º C (- 4º F)
Winter in extremely cold region Pure washer fluid - 30º C (- 22º F)

Pure washer fluid comes in two types: for -10º C (14º F) (for general use) and for -30º C (-22º F) (cold regions).
Use pure washer fluid according to operation area and season.

3-38 D51EX/PX-22
 MAINTENANCE
CHECKING AIR CONDITIONER
(Machines equipped with cab)
CHECK LEVEL OF REFRIGERANT

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

The sight gauge (a) is on the stay at the left rear of the machine.
While the air conditioning is operating occasionally check this sight
glass for color changes. The normal color in the sight gauge window
should be blue. However, if you notice the sight glass has a pink color
then the receiver dryer and air conditioning system is saturated with
moisture (wet) and needs servicing. In this case contact your Komatsu
distributor for repairs.

With air conditioning operating:

l (A) Blue, the system is functioning normally.
l (B) Pink, Receiver dryer needs replacement
(system needs repair or servicing).

Remark
Bubbles or a foggy appearance in the sight glass do not
indicate a low refrigerant charge. This is normal for
refrigerant R134, do not add refrigerant to the system. Doing
so will damage the air conditioning system.

OPERATING AIR CONDITIONER OFF-SEASON

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

D51EX/PX-22 3-39
MAINTENANCE
REPLACE WIPER BLADE
If the blade is damaged, it will not wipe the window clean, so replace the blade.
REPLACEMENT
Replace wiper blades in four locations on cab.

FRONT WIPER
Remove screw (1), then remove the blade.
Install a new front blade, then tighten screw (1) securely.

DOOR, REAR WIPER

Door blades are hooked at portion (A), move the blade in the direction
of the arrow to remove it.

3-40 D51EX/PX-22
 MAINTENANCE
Rear blade is hooked at portion (A), move the blade in the direction of
the arrow to remove it.
Install the new blade and hook it securely in place.

RELEASING INTERNAL PRESSURE ON HYDRAULIC SYSTEM

l The hydraulic system is always under internal pressure, so when inspecting or replacing the piping or
hoses, always release the pressure in the circuit before starting. If the pressure is not released, high
pressure oil may spurt out and cause serious personal injury.

l The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
Wait for the temperature to go down before starting the operation.

l When the oil filler cap is removed, oil may spurt out, so turn the cap slowly to release the pressure
before removing the cap.

Stop the machine on firm level ground.

Lower the blade to the ground, then stop the engine.
To release the internal pressure, Turn ignition switch to the ON position.
Move the work equipment lock lever to the UNLOCKED position.
Move the blade control lever to the float position (it will release when
accumulator pressure is drained)
Lower ripper to the ground (if equipped)

Remark
The accumulator no longer provides pilot pressure once the
work equipment lever returns to the NEUTRAL position after
about one minute.
Loosen oil filler cap (F) at the top of the hydraulic tank slowly to release the internal pressure.

D51EX/PX-22 3-41
MAINTENANCE
BLEEDING AIR FROM HYDRAULIC SYSTEM
After replacing or cleaning the hydraulic oil, filter element, or strainer, bleed the air from the hydraulic circuit.
See “STARTING THE ENGINE” on page 2-77“.
Since the engine must be started and the blade must be operated, See “BLADE CONTROL LEVER” on page 2-35.
BLEEDING AIR FROM PUMP
1. Remove hydraulic cap from tank.
2. Remove floor mat and cover to access bleeder plug (1)

3. Loosen air bleed plug (1) installed to the drain port and check that
oil oozes out (air bleeding is completed).
l Plug torque: 11.8 - 14.7 Nm (9 - 14 ft/lbs)
4. After completion of the air bleeding operation, tighten the air bleed
plug.
5. Reinstall cap on the hydraulic tank.
6. Reinstall foot cover and floor mat.
Remark
If the pump is run when the pump case is not full of oil, there
will be abnormal generation of heat, and this will lead to
premature failure of the pump.
7. Start the engine and run for ten minutes at low idle. For details, see
““STARTING THE ENGINE” on page 2-77“.
8. After running for ten minutes at low idle, move to the next
operation.

BLEEDING AIR FROM CYLINDERS

1. Run the engine at low idle, and extend and retract each cylinder four to five times, taking care that a cylinder is not moved
to the end of its stroke. (Stop the cylinder approximately 100 mm (3.9 in) short of its stroke end).
2. Next, operate each cylinder three to four times to the end of its stroke.
3. Finally, at high idle operate each cylinder three to five times to the end of its stroke to completely remove the air.

Remark
If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken
inside the cylinder may cause damage to the piston packing.

OPERATION
1. After completing the bleeding of the air, stop the engine, and wait for at least five minutes before starting operations. This
will release the bubbles in the oil inside the tank.
2. Check that there is no oil leakage, and wipe off any oil that has been spilled.

3-42 D51EX/PX-22
 MAINTENANCE
CLEAN, CHECK RADIATOR FINS
If the radiator fins become clogged or the radiator is clogged by dirt, clean and inspect.
CLEANING BY ROTATING COOLING FAN IN REVERSE DIRECTION
Remark
Dirt and dust will fly when the cooling fan is rotated in reverse, so be extremely careful.
To make it easier to remove the dirt, remove the cover under the radiator and be careful not to let the dirt
accumulate at the front of the radiator.
If it is needed to stop the engine when the cooling fan is rotating in reverse, run the engine at low idling before
stopping it.
Rotating the cooling fan in reverse makes it possible to blow out the dirt stuck to the radiator or cooler.
1. Turn ignition switch (1) to the OFF position and stop the engine.

2. Set parking brake lever (7) to the LOCK position to apply the
parking brake.

D51EX/PX-22 3-43
MAINTENANCE
3. Remove ten bolts, then remove covers (b).

4. Open the two doors on the hydraulic tank (2).

5. Open the door on the fuel tank (3).

6. Turn ignition switch (1) to the ON position.

7. Press the cleaning portion of fan rotation selector switch (1).

3-44 D51EX/PX-22
 MAINTENANCE
8. Press the cleaning portion of fan rotation selector switch (1).

9. Check that fan operation confirmation lamp (6) lights up.

l When the engine is running, even if the fan rotation selector switch
is operated, the direction of rotation of the fan will not change.
l Fan operation confirmation lamp (6) flashes several times to inform
the operator that the direction of rotation of the fan has not been
switched.
l When the fan operation confirmation lamp (6) is lighted up (when
the fan is rotating in reverse), the machine cannot travel.
l When cleaning, leave the parking brake applied.
10. Turn ignition switch (1) to the START position and start the engine.
The cooling fan will rotate in reverse.
11. Run the engine at high idling for three minutes.
12. Decide on the length of time for high idling according to the
condition of clogging.
13. After completing the cleaning, run the engine at low idling for approximately ten seconds.
14. Turn ignition switch (1) to the OFF position and stop the engine.
15. Close all three doors on the tanks.
16. Turn ignition switch (1) to the ON position.
17. Check that fan operation confirmation lamp (6) has gone out, then start the engine. The fan will rotate in the normal
direction.
18. Close and bolt bottom doors.

CLEANING WITH COMPRESSED AIR

Directing compressed air, pressurized water, or steam directly at your body, or using these for causing
dust to fly may cause personal injury. Always wear protective glasses, anti-dust mask, and other
protective equipment.
When carrying out cleaning, always stop the engine and check that the fan is not rotating. If you touch the
fan when it is rotating, it will cause serious personal injury.

If the radiator fins become clogged or the radiator is heavily clogged by dirt, use compressed air to clean the radiator.
Remark
To make it easier to remove the dirt, remove the cover under the radiator and be careful not to let the dirt
accumulate at the front of the radiator.

D51EX/PX-22 3-45
MAINTENANCE
1. Remove ten bolts then remove covers (b).
2. Open all three doors on the tanks.

l Remove four bolts (6) and remove lower part of grill.

l Do not remove the two bolts marked (A). This will cause the fan
motor bracket to separate from the grille.

Do not separate the grill assembly from the fan assembly.

Doing so may cause the fan assembly to spring open
causing injury.

3. Lift up the upper part of the radiator grill to open it. The lower sec-
tion will come off.
l Open radiator grill to the fully open position, check to be sure the
lock is applied, then release the grill.

Be sure rear grill is locked in place before proceeding under

this grill. Failure to do so may result in severe injury.

4. Use compressed air to blow out the mud, dirt, or leaves that are
clogging the radiator fins.
5. Check the hydraulic cooler hoses. If any hose is cracked or
hardened by age, replace with a new hose. Also check and tighten
all loose hose clamps.
6. Lower the radiator grill to close it.

3-46 D51EX/PX-22
 MAINTENANCE
l When closing the radiator grill, push grill up, then push lock
release (2) up in the direction shown by the arrow to release the
lock, then close it. Install the four bolts (6) with lower part of
radiator grill.

CHECKS BEFORE STARTING

For details of the following items, see ““PRECAUTIONS BEFORE STARTING WORK OPERATIONS” on page 2-61“.
l Check coolant level, add coolant.
l Checking with monitor.
l Check fuel level, add fuel.
l Check oil level in engine oil pan, add oil.
l Check, clean water separator.
l Check oil level in hydraulic tank, add oil.
l Check electric wiring around engine harness. (this item should be checked every 500 hours).
l Check that lamps light up.
l Check horn sound.
l Check of operation of backup alarm.

D51EX/PX-22 3-47
MAINTENANCE
EVERY 50 HOURS MAINTENANCE

DRAINING SEDIMENT FROM FUEL TANK

Carry out this check before operating the machine.
Prepare a container to catch the fuel that is drained.
1. Open drain valve (1) inside the fuel tank door, and drain the
sediment and water accumulated at the bottom together with the
fuel.
2. When doing this, be careful not to get fuel on yourself.
Remark
Be sure to place hose through hole in frame before
draining. When clear fuel comes out, close drain valve (1)

3-48 D51EX/PX-22
 MAINTENANCE
EVERY 250 HOURS MAINTENANCE

CHECK OIL LEVEL IN FINAL DRIVE CASE

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool
down before starting the operation.
If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.

CHECKING FINAL DRIVE OIL LEVEL

If the oil level in the drive is low, noise will be generated and there will
be seizure, check the oil level and add oil as follows.
l Place machine in a level position. move the track until final
drive cover shows indication “TOP” in the top position.
l Remove plug (1) and check oil level. Normal oil level should
be even with the bottom of the plug hole.
l If oil oil level is low, add oil through port (1) until it begins to
drainout.

LUBRICATING
If dirt or sand is found due to work in soft ground, carry out greasing
every ten hours of operation.
1. Lower the blade to the ground, then stop the engine.
2. Using a grease pump, pump in grease through the grease fittings
shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.
Remark
Items indicated with a ♦ require service every 50 hours of
operation.

(1) ♦ Lift cylinder bottom pin (one place).

(2) ♦Lift cylinder head pin (two places).
(3) Angle cylinder bottom pin (two places).
(4) ♦Frame mounting pin (two places).
(5) ♦Angle cylinder head pin (two places).
(6) Tilt cylinder head pin (one place).
(7) Tilt cylinder bottom pin (one place).

D51EX/PX-22 3-49
MAINTENANCE
(8) ♦Frame center ball (two place).
(9) ♦ Rod pin (1 place).

GREASE EQUALIZER BAR SIDE PIN

Greasing locations (2 places).
Grease fitting (9): Front of carrier roller support on left and right sides
of machine.
1. Remove all dirt from the top of the track frame and cover.
2. Clean the grease fitting, then supply grease to that fitting with a
grease pump.
Remark
Supply shots of grease (Operate the grease pump lever to
each grease fitting, and check that grease is freshly
discharged through the seal lip.If grease is not freshly
discharged through the lip, continue supplying grease until it
is discharged.
GREASE EQUALIZER BAR CENTER PIN
(1 place).
♦One grease fitting (8) is under the cab on left side of machine.
After cleaning the grease fitting, use a grease pump to add grease.

♦ Two grease fittings (9) on each side of the machine.

After cleaning the grease fitting, use a grease pump to add grease.

Remark
Items indicated with a ♦ require service every 50 hours of
operation.

3-50 D51EX/PX-22
 MAINTENANCE
CHECK LEVEL OF BATTERY ELECTROLYTE
Perform this inspection before operating the machine.

The battery generates flammable gas and there is danger of explosion. Do not bring fire or sparks near the
battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of
water and consult a doctor.
The battery in this machine is not serviceable. If the battery will not charge, load test the battery and
replace the battery if it is found to be defective.

l Inspect the battery charge indicator at least once a month and follow the basic safety procedures given below.
Open cover (1) at the rear left side of the machine. The battery is inside.

CHECKING THE BATTERY

1. Inspect the indicator sight glass on the top of the battery.
l If the indicator is green then the battery is in good condition.
l If the indicator is clear or discolored, replace the battery.
2. Check the condition of the battery terminals for evidence of
corrosion. If corrosion is found clean battery with appropriate
cleaning solution.

D51EX/PX-22 3-51
MAINTENANCE
CHECK BRAKE PERFORMANCE

If the machine moves during the following operation, please contact your Komatsu distributor for repairs
immediately.

Before starting the engine, check that the area around the machine is safe, then do as follows:
1. Start the engine.

2. Set work equipment lock lever to the FREE position then operate
blade control lever (2) to raise the blade.
3. Leave the work equipment lock lever to the FREE position.

3-52 D51EX/PX-22
 MAINTENANCE
4. Set parking brake lever to the FREE position.

5. Depress brake pedal fully (4) and move travel lever (5) in 1st.
6. Operate fuel control dial to gradually raise the engine speed to full
speed.
7. If the machine does not move with the above operation and no error
appears on the monitor panel, the brakes are correct.

D51EX/PX-22 3-53
MAINTENANCE
AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)
(Machines equipped with cab).
Clean the air conditioner air filter if it becomes clogged or if there is dirt or oil stuck to it.
In places where there is a lot of dust, clean the air filter once a week. In addition, clean the air conditioner air filter at the same
time, when cleaning the engine air cleaner.
1. Open the inspection cover at the rear of the machine, then turn knob
(1) and remove the fresh air filter.

2. Turn knob (2) at the rear of the operator's seat and remove the
recirculated air filter.
3. Clean the filter with compressed air. If there is oil on the filter or it
is extremely dirty, wash the filter in a neutral agent. After washing
with water, dry thoroughly before using.

Remark
If the filter cannot be cleaned, replace the filter with a new
one.

3-54 D51EX/PX-22
 MAINTENANCE
EVERY 500 HOURS MAINTENANCE

Maintenance for every 50 and 250 hours service should be carried out at the same time.

ENGINE WIRING HARNESS

Inspect the condition of the engine wiring harness. If damaged or deteriorated contact your Komatsu distributor.

The machine is equipped with an electronically controlled engine, high voltage is used to control fuel
injection, (110 - 130 V) for the fuel injector drive. Never handle the engine wiring harness while the engine
is running, tamper with or modify this circuit, severe injury may result due to the high voltage and amps in
the circuit. Always use caution when working around this circuit.

REPLACE FUEL PRE-FILTER CARTRIDGE

After the engine has been operated, all parts are at high temperature, so do not replace the filter
immediately. Wait for all parts to cool down before starting the operation.
High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pressure
go down before replacing the filter.
Do not bring any fire or flame close.

Remark
Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When
replacing the filter cartridge, always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems
with the injection system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of
dirt. If dirt is stuck to any part, use fuel to wash it off completely.

D51EX/PX-22 3-55
MAINTENANCE
l Prepare a container to catch drain fuel.
l Prepare a filter wrench.
1. Turn valve (6) in the fuel line to the closed position.

2. Open the front grill of the machine.

Do not operate the work equipment with the engine service

doors in the open position, damage to the service doors or
hood may result.

3. Set the container to catch the fuel under the pre-filter cartridge.
4. Loosen drain valve (2), then drain all the water and sediment in the
transparent cap (3) and also the fuel accumulated in filter cartridge
(4).
5. Remove connector (5). Wrap the removed connector in a vinyl bag
to prevent water from getting on it.
6. Using a filter wrench, turn transparent cap (3) to the left to remove
it. (This cap is used again).
7. Using a filter wrench, turn cartridge (4) to the left to remove it.
8. Install transparent cap (3) to the bottom of the new filter cartridge.
(When doing this, always replace O-ring).

Remark
If transparent cap is showing signs of deterioration, replace cap with a new one.
9. When installing, apply oil to the packing surface and bring the packing surface into contact with the seal surface of filter
cartridge (4) and then tighten it further by 1/4 - 1/2 turns.
10. If the transparent cap is tightened too much, the O-ring will be damaged and this will cause leakage of fuel; if it is not
tightened enough, fuel will leak through the gap at the O-ring. To prevent these problems, always tighten securely to the
fixed tightening angle.

Remark
Do not remove center cap (B) until you are ready to install the
filter.
11. Carefully fill the fuel filter through the outside holes (a) with clean
diesel fuel before installing the filter.
12. Remove the center cap plug and install the fuel filter. When
installing, tighten until the packing surface contacts the seal surface
of the filter holder, then tighten it 3/4 of a turn.
13. If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of fuel. If the filter cartridge
is too loose, fuel will also leak from the packing, so always tighten
the correct amount.
14. When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
15. Check that the drain valve (2) is tightened securely.
16. Remove the vinyl bag covering connector (5), then connect connector.

3-56 D51EX/PX-22
 MAINTENANCE
Remark
If water gets on connector (5), the sensor may malfunction
and the water separator monitor may flash. When removing
connector (5), be careful not to let any water get on it.
If water should get on connector (5), dry it thoroughly before
connecting it again.
17. Set valve (6) at the front of the fuel filter in the OPEN position.
18. After completing the replacement of filter cartridge (4), bleed the
air.

l Bleed the air as follows:

19. Fill the fuel tank with fuel to the position where the float is at the
highest position).
20. Loosen the knob of feed pump (7), pull it out, then pump it in and out until the movement becomes heavy.

Remark
It is not necessary to remove the plug at the top of the fuel pre-filter and fuel main filter.
After the engine runs out of fuel, use the same procedure to operate feed pump (7) and bleed the air.
21. After finishing to bleed air, push in the knob of feed pump (7) and tighten it.
22. After replacing the filter cartridge, start the engine and run it at low idling for ten minutes. Check the filter seal surface
and the transparent cap mounting surface for fuel leakage. If any leakage of fuel is found, check the tightening condition
of the filter cartridge. If there is still leakage of fuel, repeat Steps 1 - 8 to remove the cartridge, then check the cartridge. If
there is any damage to the packing surface or embedded foreign material, replace the cartridge with a new part and repeat
the procedure for Steps 9 - 21.

D51EX/PX-22 3-57
MAINTENANCE
CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTER CARTRIDGE

Parts and oil are at high temperature immediately after the engine is stopped and may cause serious
burns. Wait for the oil temperature to go down before performing this operation.

l Refill capacity: 20 liters (5.28 US gal)

l Prepare a socket wrench and filter wrench.
1. Remove front cover (1) and pull out the drain hose, then put the
outlet end of the hose in a container to catch the drained oil.

Do not operate the work equipment with the engine service

doors in the open position, damage to the service doors or
hood may result.

2. Loosen drain valve (a) and drain the oil.

3. Check the drained oil, and if there are excessive metal particles or
foreign material, please contact your Komatsu distributor.
4. After draining oil pan tighten drain valve (a) and return the hose to
its original position.
5. Install cover (1) securely in place.

6. Remove the six bolts on the engine side cover (1) at the right side of
the machine.

7. Using a filter wrench, turn filter (5) cartridge to the left to remove
it.
8. To prevent getting oil on yourself, do not carry out this operation
from immediately under the cartridge.
9. Clean the filter holder, fill the new filter cartridge with clean oil,
coat the thread and packing surface of the new filter cartridge with
clean oil (or coat it thinly with grease), then install it to the filter
holder.
Remark
Check that there is no old packing stuck to filter holder. If
there is any old packing remaining on the filter holder, it will
cause oil leakage.

3-58 D51EX/PX-22
 MAINTENANCE
10. When installing the filter cartridge, bring the packing surface into
contact with the filter holder, then tighten a further 3/4 to one turn.
11. After replacing the filter cartridge, add oil through oil filler (F) until
the oil level is between the H and L marks on the dipstick (G).
12. Run the engine at idle for a short time, then stop the engine, and
check that the oil level is between the H and L marks on the
dipstick. For details. See “PRE-OPERATIONAL CHECKS” on
page 2-61“.

Do not operate the work equipment with the engine service

doors in the open position, damage to the service doors or
hood may result.

D51EX/PX-22 3-59
MAINTENANCE
EVERY 1000 HOURS MAINTENANCE
Maintenance for every 50, 250 and 500 hours should be carried out at the same time.

CHANGE OIL IN FINAL DRIVE CASE

The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool
down before starting the operation.
If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.

l Prepare a flex handle.

l Refill capacity: each 4.0 liters (1.06 US gal).
1. Set the TOP mark at the top, with the UP mark and plug (2)
perpendicular to the ground surface.
2. Set a container under plug (2) to catch the oil.
3. Remove plugs (2) and (1) with the flex handle and drain the oil.

Remark
Check the O-rings in the plugs for damage. If necessary,
replace with new ones.
4. Tighten plug (2).
5. Add oil through the hole of plug (1).
6. When oil begins to overflow from the plug (1) hole, install plug (1).
l Tightening torque of plugs (1) and (2): 68.6 ± 9.8 Nm (50.6 ±
7.2 lbft).

CHECK ALTERNATOR BELT TENSION

Since inspection and replacement of the fan belt requires special tools, contact your Komatsu distributor.

CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS

Please ask your Komatsu distributor to check the tightening of the clamps between the air cleaner - turbocharger - after cooler
- engine.

3-60 D51EX/PX-22
 MAINTENANCE
CHECK FOR LOOSE ROPS MOUNT BOLTS
Check that the bolts are not loose and that there is no damage. If any
bolt is loose, tighten it to the following torque. If there is any damage,
replace the bolt with a genuine Komatsu part.

l Tightening torque:
l Bolt (1): 785 to 980 Nm (785 to 981 lbft).
l Bolt (2): 785 to 980 Nm (785 to 981 lbft).

REPLACE PRE AND MAIN FUEL FILTER CARTRIDGES

l After the engine has been operated, all parts are at high temperature, so do not replace the filter
immediately. Wait for all parts to cool down before starting the operation.

l High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.

l Do not bring any fire or flame close.

Remark
Genuine Komtsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When
replacing the filter cartridge, always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems
with the injection system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of
dirt. If dirt is stuck to any part, use fuel to wash it off completely.

D51EX/PX-22 3-61
MAINTENANCE
l Prepare a container to catch drain fuel.
l Prepare a filter wrench.
1. Open the grill at the front side of the machine.

Do not operate the work equipment with the engine service

doors in the open position, damage to the service doors or
hood may result.

2. Set the container to catch the fuel under the filter cartridge and
hose.
3. Close valve (6) before proceeding.

4. Loosen drain valve (2), then drain all the water and sediment in the
transparent cap (3) and also the fuel accumulated in filter cartridge
(4).
5. Remove connector (5). Wrap the removed connector in a vinyl bag
to prevent water from getting on it.
6. Using a filter wrench, turn transparent cap (3) to the left to remove
it. (This cap is used again).
7. Using a filter wrench, turn cartridge (4) to the left to remove it.
8. Install transparent cap (3) to the bottom of the new filter cartridge.
(When doing this, always replace O-ring).
9. Clean the filter holder, coat the packing surface of the new filter
cartridge thinly with oil, then install the filter cartridge to the filter holder.
l Replace inner seal (8) with a new part.

10. When installing, tighten until the packing surface contacts the seal
surface of the filter holder, then tighten it 3/4 of a turn.
l If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing,
always tighten the correct amount.

Remark
When adding fuel, do not remove cap (B). Always add fuel
from the 8 small holes (A) on the dirty side.
After adding fuel, remove cap (B) and install the fuel filter.
Always fill with clean fuel. Be careful not to let any dirt or dust
get into the fuel. In particular, center portion is the clean side,
so do not remove cap (B) when adding fuel. Be careful not to
let dirt or dust get into center portion on the clean side.

3-62 D51EX/PX-22
 MAINTENANCE
11. Using a filter wrench, turn secondary filter cartridge (8)
counterclockwise to remove it.

Remark
Do not fill the new filter cartridge with fuel.
12. When installing secondary filter (8) tighten until the packing
surface contacts the seal surface of the filter holder, then tighten it
3/4 of a turn.
l If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing,
always tighten the correct amount.
13. Open valve (6) at the front of the primary fuel filter.
14. After completing the replacement, bleed the air.

l Bleed the air as follows:

15. Fill the fuel tank with fuel (to the position where the float is at the
highest position).
16. Loosen the knob of feed pump (7), pull it out, then pump it in and out until the movement becomes heavy.

Remark
It is not necessary to remove the plug at the top of the fuel pre-filter and fuel main filter.
After the engine runs out of fuel, use the same procedure to operate feed pump (4) and bleed the air.
17. Push in the knob of feed pump (7) and tighten it.
18. After replacing the filter cartridge, start the engine and run it at low idling for 10 minutes.
l Check the filter seal surface for fuel leakage. If any leakage of fuel is found, check the tightening condition of the
filter cartridge. If there is still leakage of fuel, repeat Steps 1 - 5 to remove the cartridge, then check the cartridge. If
there is any damage to the packing surface or embedded foreign material, replace the cartridge with a new part and
repeat the procedure for Steps 6 - 14.

D51EX/PX-22 3-63
MAINTENANCE
EVERY 2000 HOURS MAINTENANCE
Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time.

CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE

The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Wait for the temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

l Refill capacity: 63 liters (16.64 US gal)

1. Lower the blade to the ground securely, stop the engine and slowly
turn the cap of oil filler to release the internal pressure. Then,
remove the cap.
2. Open the left rear side cover on the hydraulic tank.

3. Set a container under the filter to catch the oil.

4. Use a filter wrench to turn charge filter cartridge (5) to the left and
remove it.

3-64 D51EX/PX-22
 MAINTENANCE
5. Set a container under the hydraulic oil drain port (6) to catch the oil
that is drained from the hydraulic tank.
6. Remove grommet (1) from bottom of hydraulic tank.
7. Attach a hose (2) to the tank drain valve outlet (6) that is long
enough to reach container for collecting the 63 L (17 gal) of
hydraulic oil.

8. Loosen drain valve (6) at the bottom of the hydraulic tank, drain the
oil, then tighten drain valve (6) again. When loosening drain valve
(6), be careful not to get oil on yourself.

9. Open the inspection cover on the right rear side at the front of the
fuel tank, then use a filter wrench to turn hydraulic filter cartridge
(7) to the left and remove it.

10. Remove two screws (9), then take out strainer (10).

Remark
Lift up the flange to take out the strainer. Turn the flange by
utilizing the slack of the rubber hose connected to the pipe.

D51EX/PX-22 3-65
MAINTENANCE
11. Remove any dirt stuck to strainer (10), then wash it in clean diesel
oil or flushing oil
12. Assemble strainer (10), tighten screws (9), then assemble piping (8)
with bolts.
13. Clean the filter holder, fill the new filter cartridge with oil, then coat
the seal and thread of the filter cartridge with oil (or coat thinly with
grease) and install.
14. After the packing surface of the cartridge touches the sealing sur-
face of the filter holder, tighten the cartridge further by about 2/3
turns.
l Use Komatsu genuine cartridge.
15. Refill the specified quantity of oil through oil filler (F).
16. After adding oil, check that the oil is at the correct level.
l For details, see “CHECKING AND ADDING OIL TO
HYDRAULIC TANK” on page 2-64“.
17. After replacing hydraulic oil and cleaning or replacing filter element and strainer, bleed air from the circuit.
l For details of the method of bleeding the air from the hydraulic circuit. See “BLEEDING AIR FROM PUMP” on
page 3-42“.

3-66 D51EX/PX-22
 MAINTENANCE
CHECK ALTERNATOR
The bearing may have run out of grease, contact your Komatsu distributor for inspection and repairs.
If the engine is started frequently, have this inspection carried out every 1000 hours.

CHECK ENGINE VALVE CLEARANCE, ADJUST

Contact your Komatsu distributor for cleaning and inspection.

REPLACE HYDRAULIC TANK BREATHER ELEMENT

The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Wait for the temperature to go down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

1. Remove the cap of oil filler at the top of the hydraulic tank.

2. Replace element (1) inside the cap.

D51EX/PX-22 3-67
MAINTENANCE
CHECKING CHARGE PRESSURE ACCUMULATOR (CONTROL CIRCUIT)

The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explo-
sion, which will lead to serious injury or damage. When handling the accumulator, always do as fol-
lows.The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic
equipment, do not stand in the direction that the oil spurts out when carrying out the operation. In addition,
loosen the bolts slowly when carrying out the operation.
l Do not disassemble the accumulator.

l Do not bring it near flame or dispose of it in fire.

l Do not make holes in it or weld it.

l Do not hit it, roll it, or subject it to any impact.

l When disposing of the accumulator, the gas must be released. Please contact your Komatsu distribu-
tor to have this work carried out.

FUNCTION OF ACCUMULATOR
The accumulator stores pressurized oil to supply the blade control PPC for a few cycles. Even after the engine is stopped, the
control circuit can be operated, so the following actions are possible.
l If the control lever is operated in the direction to lower the work equipment, it is possible for the work equipment to go
down under its own weight.
l The pressure in the hydraulic circuit can be released.
l The accumulator is installed to the position shown in the diagram on the right.

CHECKING FUNCTION OF ACCUMULATOR

Replace the accumulator (1) every 2 years or every 4000 hours, which-
ever comes sooner.
Check the accumulator (1) function as follows.
1. Stop the machine on firm, level ground.
2. Operate the parking brake lever to LOCK position.
3. Raise the work equipment (blade) to the maximum height.

Remark
Carry out the following procedure for lowering the blade to
the ground within 15 seconds after stopping the engine.
When the engine is stopped, the pressure inside the
accumulator gradually goes down, so this inspection can be
carried out only immediately after the engine is stopped.
4. While holding the work equipment at the highest position, turn the engine ignition switch key to OFF position.
5. Turn the engine ignition switch key to ON position (Do not start the engine).
6. Turn the work equipment lock lever to FREE position.
7. Operate the blade control lever fully in the direction to lower the blade.

Remark
Check that the area around the machine is safe, then operate the blade control lever to the LOWER position.

3-68 D51EX/PX-22
 MAINTENANCE
8. Check that the work equipment goes down to the ground under its own weight.
9. This completes the inspection.
Remark
If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become
impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the machine.
In the following cases, the charge pressure of the accumulator has gone down. Please contact your Komatsu distributor.
l Work equipment does not go down.
l Stops while going down.

RELEASING PRESSURE IN HYDRAULIC CIRCUIT

Stop the machine on firm level ground.
Lower the blade to the ground, then stop the engine.
To release the internal pressure, Turn ignition switch to the ON position.
Move the work equipment lock lever to the FREE position. Move the
work equipment to the FLOAT position.
Remark
The accumulator no longer provides pilot pressure once the
work equipment lever returns to the NEUTRAL position after
about one minute.
Loosen oil filler cap (F) at the top of the hydraulic tank slowly to release
the internal pressure.

CHECKING PIVOT SHAFT OIL LEVEL

Place machine in a level position.
l Remove plug (3) and check oil level. Normal oil level should
be even with the bottom of the plug hole.
l If oil must be added, add oil to bottom level of plug hole.
l If oil is too high or needs to be drained, drain oil to bottom
level of plug hole.

CHECKING IDLER OIL LEVEL

Place machine in a level position.
l Remove plug (4) and check oil level. Normal oil level should
be even with the bottom of the plug hole.
l If oil must be added, add oil to bottom level of plug hole.

D51EX/PX-22 3-69
MAINTENANCE
EVERY 4000 HOURS MAINTENANCE
Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be carried out at the same time.

CHECK WATER PUMP

Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any problem is found, please
contact your Komatsu distributor for repairs or replacement.

CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.

CHECK STARTING MOTOR

Contact your Komatsu distributor to have the starting motor checked.
If the engine is started frequently, have this inspection carried out every 1000 hours.

3-70 D51EX/PX-22
 MAINTENANCE
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)
Replace the accumulator (1) every two years or every 4000 hours, whichever comes sooner.

The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an
explosion, which will lead to serious injury or damage. When handling the accumulator, always do as
follows. The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic
equipment, do not stand in the direction that the oil spurts out when carrying out the operation. In addition,
loosen the bolts slowly when carrying out the operation.
l Do not disassemble the accumulator.

l Do not bring it near flame or dispose of it in fire.

l Do not make holes in it or weld it.

l Do not hit it, roll it, or subject it to any impact.

l When disposing of the accumulator, the gas must be released. Please contact your Komatsu distribu-
tor to have this work carried out.

If operations are continued after the performance of the accumulator has

dropped, it will be impossible to release the remaining pressure in the
hydraulic circuit if there should be a failure on the machine. Contact
your Komatsu distributor to replace the accumulator.

CHECKING FOR MISSING FUEL SPRAY CAP, HARDENING OF RUBBER

The fuel spray prevention caps (14 places) on the fuel injection piping and both ends of the high-pressure piping act to prevent
the fuel from coming into contact with high-temperature parts of the engine and causing a fire if the fuel should leak or spray
out. Check visually and touch by hand to check that there are no missing caps, loose bolts or hardening of the rubber. If there
are any problems, the parts must be replaced. In this case, please ask your Komatsu distributor to carry out replacement.

D51EX/PX-22 3-71
MAINTENANCE

3-72 D51EX/PX-22
 5OPTIONAL ATTACHMENTS

D51EX/PX-22 5-1
OPTIONAL ATTACHMENTS
AUTHORIZED OPTIONAL EQUIPMENT
Komatsu machines can be supplied with optional equipment in addition to the standard equipment. If optional equipment is
installed and used on your machine, read and study all operations and safety information instructions relating to the optional
equipment you will be using. Failure to do so may result in damage to the equipment or injury to the operator. Komatsu cannot
be held liable for damage, accident or reduction of machinery performance due to the application and use of unauthorized
equipment. Always use authorized equipment on your machine.

BASIC PRECAUTIONS
When installing or using optional equipment, always contact your Komatsu Dealer first. Be sure the personnel installing or
using the optional equipment are trained and authorized to do so. Listed are some basic safety precautions that must be
observed when installing or using optional equipment:

• Install or remove optional equipment on a firm level surface.

• Be sure the equipment you are installing is in good operating condition.
• When operations are performed using two or more personnel, agree to a set communication signals in advance and stick to
them.
• Always use an overhead crane when lifting equipment weighing more than 25 kg (55 lb).
• Be aware, the center of gravity on your machine will change when optional equipment is installed.
• Make sure your machine is rated for the optional equipment being installed.
• When using optional equipment be sure all non-authorized personnel are at least 12m (40 ft) away from your work
location.

5-2 D51EX/PX-22
 OPTIONAL ATTACHMENTS
DELUXE SEAT

When adjusting the position of the operator's seat, always set the work equipment lock lever to the LOCK
position to prevent any accidental contact with the control levers.

• Always adjust the operator's seat before starting each operation or when the operators change shift.
• When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully
depressed.

(A) Fore-and-aft adjustment

Pull lever (1), set the seat to a position where it is easy to operate,
then release the lever.
Fore-aft adjustment: 160 mm (6.3 in) (8 stages).

(B) Weight adjustment of seat

Turn knob (2) under the seat to match the weight adjustment scale
with your own weight.
The weight can be adjusted within a range of 50 to 120 kg (110 to
265 lb).

Remark
If you want to make the seat softer, turn the weight adjust-
ment to a lower weight; if you want to make the seat harder,
adjust to a higher weight. When operating on uneven surfaces, adjust the seat to a harder setting.

(C) Adjust reclining angle

Pull up lever (3) and set the seat back to a position which is comfortable for operation, then release the lever.
Sit with your back against the seat back when adjusting. If your back is not touching the seat back, the seat back may
suddenly move forward.

Remark
The seat can be reclined more when the seat is pushed to the front. The amount of reclining decreases as the
seat is pushed back, so when moving the seat back, return the seat back to the upright position.

(D) Height adjustment of seat

Turn lever (4) to adjust the height of the seat.
If the lever is turned clockwise, the seat is heightened. If the former is turn counterclockwise, the latter is lowered.
If you apply your weight to the seat, the lever becomes heavy. Accordingly, do not apply your weight.
After adjusting the height, release the lever to lock the seat.
Height adjustment distance: 50 mm (2.0 in)

(E) Adjusting direction of seat

Pull up lever (5) to unlock the seat. The seat can then be turned 15° to the right.
After changing the direction of the seat, return the lever securely to lock the seat.
Change the direction of the seat to the right for the ease of operation of the ripper.

D51EX/PX-22 5-3
OPTIONAL ATTACHMENTS
FORESTRY KIT
This kit is used in wooded operations where the possibility of tree branches or falling vegetation may damage the machine or
injure the operator.
When using the machine for land clearing or in forest applications be sure to have this kit installed on the machine before
performing any operations.

Do not use a dozer for clearing trees or tall object unless the
machine has a protective cage installed. Injury to the
operator may result. If any part of the forestry kit system
should become damaged, replace the damaged component
before using the machine.

5-4 D51EX/PX-22
 OPTIONAL ATTACHMENTS
CABIN POLYCARBONATE PANEL FRONT

• Cleaning And Maintenance Instructions

Periodic cleaning using proper procedures and compatible cleaners is recommended to prolong the service life. For general
cleaning, it is recommended that the following instructions and cleaning agents be used. These procedures and cleaners are
also recommended for use on the untreated, interior surface of the polycarbonate panel sheet.

• Cleaning Procedures
A. Rinse sheet with lukewarm water.

B. Wash sheet with a solution of mild soap or household detergent and lukewarm water using a soft cloth or sponge and
gently wash to loosen any dirt and grime. DO NOT SCRUB or use brushes or squeegees; the coating on
polycarbonate panel sheet is UV resistant. It does not prevent scratching or abrasion.

C. Repeat rinse and dry with a soft cloth to prevent water spotting.

• Points To Remember:
• Don't use abrasive or highly alkaline cleaners.
• Never scrape the panel with squeegees, razor blades or other sharp instruments.
• Don't clean panel in the hot sun or at elevated temperatures as this can lead to staining.

• Cleaning agents which have been found to be compatible with polycarbon panel sheet
• Freon T.F., Joy1, Palmolive Liquid2, Top Job1, VM&P grade Naptha, Windex with Ammonia D3

• Cleaning agents which have been found to be incompatible with polycarbon panel sheet.
• Lysol4, Pinesol5, Butyl Cellosolve, Isopropanol, Formula 4096

Remark
If a material is found to be incompatible in a short-term test, it will usually be found to be incompatible in the
field. The converse, however, is not always true. Favorable performance is no guarantee that actual end-use
conditions have been duplicated. Therefore, these results should be used as a guide only and the products
must be tested under actual end-use conditions by the user.

D51EX/PX-22 5-5
OPTIONAL ATTACHMENTS
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT
Equipping the fire extinguisher and the first-aid kit at the illustrated
position needs brackets (if equipped).
The fire extinguisher and the first-aid kit can be installed to the positions
shown in the following illustration.
For parts that are required to install them in your machine, please
contact your Komatsu distributor.

When installing a fire extinguisher, install it in the position shown in the

diagram.
When installing a first aid box, install it in the position shown in the
diagram.

5-6 D51EX/PX-22
 SPECIFICATIONS 4

D51EX/PX-22 4-1
SPECIFICATIONS
SPECIFICATIONS

Item Unit D51EX-22 D51PX-22

Machine weight kg (lb.) 12,600 (27,558) 13,100 (28,881)

Engine name ⎯ Komatsu SAA6D107E-1 Diesel engine
Engine horsepower kW (HP)/rpm 97 (130)/2,200
A Overall length mm (ft. in.) 48,00 (15.ft. 7.in.)
Including antenna 3,177 (125.1)
B Overall height mm (in.)
Top of cab/ROPS 2,997 (118)
C Overall width mm (in.) 3,045 (120) * 3,350 (132)
Travel speed Forward: 1st/2nd/3rd km/h (MPH) 3.4/5.6/9.0 (2.1/3.5/5.6)
(Quick shift mode) Backward: 1st/2nd/3rd km/h (MPH) 4.1/6.5/9.0 (2.5/4.0/5.6)
Travel speed Forward km/h (MPH) 0.8 - 9.0 (0.5 - 5.6)
(Variable shift mode) Backwards km/h (MPH) 0.8 - 9.0 (0.5 - 5.6)

* Machines equipped with narrow blade

OPERATING WEIGHT
(Approximate)

H Tractor Weight:
Including rated capacity of lubricant, coolant, full fuel tank, operator, and standard equipment.
D51EX-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,100 kg (24,471 lb)
D51PX-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,500 kg (25,353 lb)
H Operating weight:
Including power angle tilt dozer, ROPS cab, operator, standard equipment, rated capacity of lubricant, coolant, and full fuel
tank.
D51EX-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,600 kg (27,778 lb)
D51PX-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,100 kg (28,881 lb)

4-2 D51EX/PX-22
 SPECIFICATIONS
MACHINE DIMENSIONS AND WEIGHTS

Spec. D51EX-22 mm (in) D51PX-22 mm (in) Spec. D51EX-22 mm (in) D51PX-22 mm (in)
A 1,280 (50.4) 1,280 (50.4) J 3,177 (125.1) 3,177 (125.1)
B 3,045 (120) 3,350 (132) K 2,997 (118) 2,997 (118)
*B 3350 (132) NA L 54 (2.1) 54 (2.1)
C 445 (18) 490 (19.3) M 1,790 (70.5) 1,880 (74)
D NA NA N 510 (20.1) 710 (28)
E 980 (39) 980 (39) O 2,300 (91) 2,590 (102)
F 520 (20.5) 520 (20.5) P 161 (6.3) 161 (6.3)
G 2,745 (108) 2,745 (108) *P 27 (1.1) NA
H 4,800 (189.1) 4,800 (189.1) Q 2,725 (107.2) 2,990 (118)
I 2,245 (88.4) 2,245 (88.4) *Q 2,990 (118) NA

* Wide blade (available on D51EX-22 only)

D51EX/PX-22 4-3
SPECIFICATIONS
MACHINE SYSTEMS SPECIFICATIONS

ENGINE

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SAA6D170E-1*

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled, 4-cycle
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged, after cooled
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bore x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 mm x 124 mm 4.21" x 4.88"
Piston displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.96 ltr 408 in3
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All speed, electronic
Horsepower
SAE J1995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gross 99 kW 133 HP
ISO 9249/SAE J1349* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Net 97 kW 130 HP
Hydraulic fan at maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Net 90 kW 120 HP
Rated rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,200 rpm
Fan drive method for radiator cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic
Lubrication System
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump, force-lubrication
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow type
*EPA Tier 3 emissions certified

4-4 D51EX/PX-22
 SPECIFICATIONS
TRANSMISSION
Travel Speed Forward Reverse
(quick shift mode)
1st. 0.- 3.4 km/hr. (0 - 2.1 mph.) 0 - 4.1 km/hr (0 - 2.5 mph.)
2nd. 0 - 5.6 km/hr. (0 - 3.5 mph.) 0 - 6.5 km/hr (0 - 4.0 mph.)
3rd. 0 - 9.0 km/hr. (0 - 5.6 mph.) 0 - 9.0 km/hr (0 - 5.6 mph.)
Travel Speed
0 - 9.0 km/hr. (0 - 5.6 mph.) 0 - 9.0 km/hr (0 - 5.6 mph.)
(variable mode)

STEERING SYSTEM

Minimum turning radius:

D51EX-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 m 7 ft 10 in
D51PX-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 m 8 ft 7 in
As measured by track marks on the ground at pivot turn.

SERVICE REFILL CAPACITIES

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 L 9.3 U.S. gal

Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 L 71.3 U.S. gal
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L 5.3 U.S. gal
Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 L 16.6 U.S. gal
Final drive
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 L 1.1 U.S. gal
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 L 1.1 U.S. gal

UNDERCARRIAGE

Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oscillating equalizer bar and pivot shaft

Track roller frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monocoque, large section, durable construction
Rollers and idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricated track rollers
H Track Shoes
Lubricated tracks. Unique seals prevent entry of foreign abrasive material into pin to bushing clearances to provide extended
service life. Track tension is easily adjusted with grease gun.

D51EX-22 D51PX-22
Number of track rollers on each side 7 7
Type of shoes (standard) Single grouser Single grouser
Number of shoes (each side) 44 44
Grouser height 54 mm (2.1 in) 54 mm (2.1 in)
Shoe width (standard) 510 mm (20 in) 710 mm (28 in)
Ground contact area 28,000 cm2 (4,340 in2) 38,980 cm2 (6,042 in2)
Ground pressure (with dozer, ROPS canopy) 44.2 kPa (6.40 psi) 33.4 kPa (4.78 psi)
Track gauge 1,790 mm (5 ft 10 in) 1,880 mm (6 ft 2 in)
Length of track on ground 2,745 mm (9 ft 0 in) 2,745 mm (9 ft 0 in)

D51EX/PX-22 4-5
SPECIFICATIONS

4-6 D51EX/PX-22
INTRODUCTION

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
APPROVED AND NON-APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
NON-APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
PRODUCT IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
ENGINE SERIAL NUMBER AND EMISSION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
SERIAL NUMBERS AND DEALER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
MODEL: D51EX/PX-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8

SAFETY

SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
GENERAL SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
GENERAL SAFETY AT JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
WORKING ON LOOSE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
FIRE CAUSED BY FUEL OR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL . . . . . . . . . . . . . 1-11
FIRE FROM ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
FIRE FROM HYDRAULIC LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
WINDSHIELD WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
ACTION IF FIRE OCCURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
DUST HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
KEEP OPERATOR'S CAB CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
LEAVING OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
PARKING BRAKE AND EQUIPMENT LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
CRUSH OR PINCH POINT DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
INSIDE OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
PRECAUTIONS WHEN USING ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
PRECAUTIONS BEFORE STARTING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
WORK SITE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
AVOIDING DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
HIGH VOLTAGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
PRECAUTIONS WHEN TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

-1
 USING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
RULES FOR TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
TRAVELING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
WORKING ON LOOSE OR UNSTABLE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
TRAVEL ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
PRECAUTIONS DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
USING DROP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
RUNNING THE MACHINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
RULES FOR REFUELING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
WORK UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
PRECAUTIONS WHEN USING HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Turn the battery disconnect switch to the OFF position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
REPAIR WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
ENGINE SYSTEM HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
BATTERY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
HANDLING HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
PRECAUTION FOR HIGH FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
HIGH TEMPERATURE AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
ROTATING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION . . . . . . . . . . . . . . . . . . 1-31
DO NOT DISASSEMBLE RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
LOADING AND SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

OPERATION

GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
VIEW OF CONTROLS AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
MONITOR BEZEL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
BASIC OPERATION OF MONITOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
CHECK MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
MONITOR CHECK ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
EMERGENCY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ENGINE OIL PRESSURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ENGINE COOLANT TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

-2
 HYDRAULIC OIL TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
HST CHARGE PRESSURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
CHARGE FILTER CLOG CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
WARNING ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
BATTERY CHARGE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
AIR CLEANER CLOGGING CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
WATER IN FUEL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
MAINTENANCE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
CONSOLE CONTROL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
SWITCH LAYOUT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
BUZZER CANCEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
INFORMATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
HEATER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
CAB LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
ACCESSORY SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
HYDRAULIC OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
DISPLAY PANEL (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
FUEL LEVEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
REVERSE TRAVEL SPEED SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
SHIFT MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
ENGINE INTAKE AIR PRE-HEAT PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
DISPLAY PANEL (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
FAN ROTATION SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
WARNING LAMP VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
WARNING LAMP (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
USING FAILURE CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
USING MAINTENANCE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
METHOD OF SELECTING EACH MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
USING OIL AND FILTER MAINTENANCE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
USING ADJUMENT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
CONTROL LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
LEVER LAYOUT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
LOCK LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
TRAVEL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
BLADE ANGLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
WORK EQUIPMENT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
DECELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
DOOR AND WINDOW SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
-3
 DOOR - OPEN LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
SASH GLASS INTERMEDIATE LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
SAFETY LOCKS AND SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
CAP, COVER WITH LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
OPENING AND CLOSING CAP WITH LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
LOCKABLE AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
SEAT POCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
ADDITIONAL FEATURES AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
AIR CONDITIONER AND FEET HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
GENERAL DESCRIPTION OF CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
BLOWER SPEED SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
TEMPERATURE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
PRECAUTIONS WHEN USING AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
FEET HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
EXPLANATION OF FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
POWER SWITCH/VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
AUTO-STORE/PRESET SCAN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
BASS CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
TREBLE CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
LOUDNESS BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
TIME/RADIO DISPLAY SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
TAPE EJECT BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
CASSETTE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
FAST FORWARD, REWIND BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
PRESET BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
METAL TAPE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
MANUAL TUNING BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
SEEK TUNING BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
BAND SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
LISTENING TO RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
LISTENING TO A CASSETTE TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
REVERSING TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
PRECAUTION WHEN USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
ASHTRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
LUNCH BOX HOLDER STRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
CUP HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
TOOL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
GREASE PUMP HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
ELECTRICAL POWER ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
FUSE CAPACITIES AND CIRCUIT NAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
PRECAUTIONS BEFORE STARTING WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
-4
 WALK-AROUND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
AIR SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
ADJUST ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
FASTENING AND REMOVING SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
ADJUSTING MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
SYSTEM “ON” CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
NORMAL OR COLD START PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
COLD WEATHER STARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
OPERATIONS AND CHECKS AFTER STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
BREAKING IN THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
WARMING UP ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
STARTING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
MOVING, STEERING, STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . 2-88
PREPARATIONS FOR MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
MOVING MACHINE FORWARD OR REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
CHANGING SPEED RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
STEERING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
NORMAL TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
MAKING A LEFT OR RIGHT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
MAKING A PIVOT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
TURNING WHILE DESCENDING A SLOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
COUNTER-ROTATION TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
STOPPING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
PARKING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
CHECK AFTER FINISHING WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
CHECK AFTER SHUTING OFF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
AVOIDING DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
HIGH VOLTAGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
PAY ATTENTION TO GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
PERMISSIBLE WATER DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
METHOD OF USING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
WHEN TRAVELING UP OR DOWN HILLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
PRECAUTIONS ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
1. BE AWARE OF FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
2. PRECAUTIONS WHEN ENGINE STOPS ON A SLOPES . . . . . . . . . . . . . . . . . . . . . . 2-103
ALWAYS KEEP THE DOORS CLOSED DURING OPERATIONS . . . . . . . . . . . . . . . . . 2-103
DO NOT MODIFY THE CAB GLASS IN ANY WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAYS . . . . . . . . . . . . . . . . . 2-103
CUTTING A GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
DOZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
BACK GRADING A SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
CUTTING HARD OR FROZEN GROUND OR DITCHING . . . . . . . . . . . . . . . . . . . . . . . 2-105
FELLING TREES, REMOVING STUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
SIDE-CUTTING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
-5
 UNDERCARRIAGE CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
OPERATION METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
MEASURING LINK PITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
MEASURING HEIGHT OF GROUSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
MEASURING OUTSIDE DIAMETER OF TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . 2-108
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
LOADING OR UNLOADING A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
PRE-TRANSPORTATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
SECURING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
COOLING SYSTEM COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115
PRECAUTIONS ON PARTICULAR JOBSITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
DISCHARGED BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
REMOVE AND INSTALL BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117
BATTERY CHARGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117
STARTING ENGINE WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118
GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
AFTER RUNNING OUT OF FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
WHEN IT IS POSSIBLE TO START ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
WHEN ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
RELEASING THE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
CONNECTING PUMP TO MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
AFTER TOWING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124
ELECTRICAL SYSTEM PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125
MONITOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-126
CHASSIS PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127
ENGINE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128
LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
BEFORE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
AFTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
MACHINES EQUIPPED WITH KOMTRAX SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131

MAINTENANCE

MAINTENANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

SERVICE METER READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
KOMATSU GENUINE REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
KOMATSU GENUINE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
WINDSHIELD WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
FRESH AND CLEAN LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

-6
 CHECK DRAINED OIL AND USED FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
WELDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
DO NOT DROP THINGS INSIDE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
DUSTY JOBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
AVOID MIXING LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
HYDRAULIC SYSTEM - AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
HYDRAULIC HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS . . . . . . . . . . . . . . . . . . . . . . 3-3
LOCKING THE INSPECTION COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
OPENING OR CLOSING RADIATOR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
LUBRICANTS, COOLANT AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
OUTLINE OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC . . . . . . . . . . . . . . . . 3-6
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
COOLING SYSTEM COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS) . . . . . . . . . . . . . . . . . . . . 3-7
OIL AND FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ELECTRIC SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
HANDLING HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
WEAR PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS . . . . . . . . . . . 3-13
LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 3-14
TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
SAFETY RELATED CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
MAINTENANCE WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CLEAN TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CLEANING THROUGH ACCESS AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CHECK ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ENGINE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
CLEANING OR REPLACING OUTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
REPLACING INNER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
CLEAN COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
FLUSHING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
TRACK SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
CHECK AND TIGHTEN TRACK SHOE BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
CHECKING AND ADJUSTING TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
IDLER GUIDE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
-7
 REVERSING OR REPLACING END BITS AND CUTTING EDGES . . . . . . . . . . . . . . . . . . . 3-35
ADJUST PLAY IN CENTER BALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
DOOR HINGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
CHECKING WINDOW WASHER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
MIXTURE RATIO OF PURE WASHER FLUID AND WATER . . . . . . . . . . . . . . . . . . . . . 3-38
CHECKING AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
CHECK LEVEL OF REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
OPERATING AIR CONDITIONER OFF-SEASON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
REPLACE WIPER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
RELEASING INTERNAL PRESSURE ON HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 3-41
BLEEDING AIR FROM HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
BLEEDING AIR FROM PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
BLEEDING AIR FROM CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
CLEAN, CHECK RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
CLEANING BY ROTATING COOLING FAN IN REVERSE DIRECTION . . . . . . . . . . . 3-43
CLEANING WITH COMPRESSED AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
EVERY 50 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
DRAINING SEDIMENT FROM FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
EVERY 250 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHECK OIL LEVEL IN FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHECKING FINAL DRIVE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
LUBRICATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHECK LEVEL OF BATTERY ELECTROLYTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
CHECK BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) . . . . . . . . . . . . . . . . . . . . . . . . 3-54
EVERY 500 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
REPLACE FUEL PRE-FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTER CARTRIDGE . . . 3-58
EVERY 1000 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
CHANGE OIL IN FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
CHECK ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS . . . . . . . . . . . 3-60
CHECK FOR LOOSE ROPS MOUNT BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
REPLACE PRE AND MAIN FUEL FILTER CARTRIDGES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
EVERY 2000 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE . . . . . . . . . . 3-64
CHECK ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
CHECK ENGINE VALVE CLEARANCE, ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
REPLACE HYDRAULIC TANK BREATHER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
CHECKING CHARGE PRESSURE ACCUMULATOR (CONTROL CIRCUIT) . . . . . . . . . . . 3-68
FUNCTION OF ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
CHECKING FUNCTION OF ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
RELEASING PRESSURE IN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
CHECKING PIVOT SHAFT OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
CHECKING IDLER OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
-8
EVERY 4000 HOURS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
CHECK WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
CHECK VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
CHECK STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
CHECKING FOR MISSING FUEL SPRAY CAP, HARDENING OF RUBBER . . . . . . . . . . . 3-71

SPECIFICATIONS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
OPERATING WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
MACHINE DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
MACHINE SYSTEMS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
SERVICE REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

OPTIONAL ATTACHMENTS

AUTHORIZED OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
DELUXE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
FORESTRY KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
CABIN POLYCARBONATE PANEL FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

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