Sead 010801

SEAM010801
Operation
& Maintenance
Manual
KOMNtbU
Komatsu America International Company
D375A=
BULLDOZER
SERIALNUMBERS
D375A=3
17001
and
UP
Operation
& Maintenance
Manual
SEAM01 0801
D375A=
BULLDOZER
SERIALNUMBERS
D375A.3
17001
and up
This materialis proprietary

to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
lt 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.
lt is recommended that customers contact their distributor for information on the latest revision.
October 1997
Copyright 1997 Komatsu America International Company
UARNINC
Unsafe use of thii 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 personnelwho come in contact with it.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects and
other reproductive harm.
1. FOREWORD
This manual provides rules and guidelines

which will help you use this machine safely and
effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been
lost or has become dirty and can not be read, request a replacement
manual from Komatsu or your
Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
Continuing improvements
in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available
information
of your machine or for questions regarding information
in this manual.
This manual may contain attachments
and optional equipment that are not available in your area.
Consult Komatsu or your Komatsu distributor for those items you may require.
A
Improper operation
injury or death.
and maintenance
WARNING
of this machine
-I
can be hazardous
and could result in serious
Operators
and maintenance
personnel should read this manual thoroughly
before beginning
operation or maintenance.
Keep this manual in a readily available place near the machine, and have all personnel involved
in working on the machine read the manual periodically.
Some actions involved in operation and maintenance
of the machine
if they are not done in a manner described in this manual.
can cause a serious accident,
The procedures and precautions given in this manual apply only to intended uses of the machine.
If you use your machine for any unintended
uses that are not specifically prohibited, you must
be sure that it is safe for you and others. In no event should you or others engage in prohibited
uses or actions as described in this manual.
Komatsu delivers machines that comply with all applicable regulations
and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and specifications
that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor
before operating the machine.
The description
l-l.
of safety is given in SAFETY INFORMATION
on page O-2 and in SAFETY from page
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents
are known to the State
of California
to cause cancer, birth
defects,
and
other
reproductive
harm.
O-l
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and
maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings
in this manual and on the machine before performing operation and maintenance.
To identify safety messages in this manual and on machine labels, the following signal words are
used.
This word is used on safety messages and safety labels where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages or labels usually describe precautions that must be taken to avoid the
hazard. Failure to avoid this hazard may also result in serious damage to the
machine.
A WARNING
This word is used on safety messages and safety labels where there is a
potentially dangerous situation which could result in serious injury or death if
the hazard is not avoided. These safety messages or labels usually describe
precautions that must be taken to avoid the hazard. Failure to avoid this hazard
may also result in serious damage to the machine.
A CAUTION
This word is used on safety messages and safety labels for hazards which could
result in minor or moderate injury if the hazard is not avoided. This word might
also be word for hazards where the only result could be damage to the machine.
This word is used for precautions that must be taken to avoid actions which
could shorten the life of the machine.
DANGER
NOTICE
Safety precautions are described in SAFETY from page l-l.

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact your
Komatsu distributor.
o-2
3. INTRODUCTION
3.1
INTENDED
USE
This Komatsu BULLDOZER is designed to be used mainly for the following work.
l
Dozing
e
Cutting into hard or frozen ground or ditching
l
Felling trees, removing stumps
l
Pushing
l
Ripping
See the section 12.10 WORK POSSIBLE USING BULL DOZER and 12.12 RIPPER OPERATION
further details.
3.2
3.3
for
FEATURES
Simple lever operation with directional, steering and gear shift joystick
Pressurized, sealed cab with air conditioner for pleasant operations
Simple check operations using monitor panel
increase in production through use of lock-up torque converter
Reduction in fuel costs and undercarriage
costs through use of mode selection system
High power engine with turbocharger
and after cooler
A flexible undercarriage
mechanism and cab mount with viscous damper are employed to improve
the ride for the operator
Low noise, high visibility design to ensure simple and safe operations
BREAKING
IN THE MACHINE
NOTICE
Before operating the machine for the first time, check that there is coolant in the radiator.
machine is delivered with no coolant in the radiator, flush the inside of the radiator thoroughly
tap water, then fill the radiator with coolant.
If the
with
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.
Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.)
During breaking in:
l
Idle the engine for 5 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.
The precautions given in this manual for operating, maintenance,
and safety procedures are only
those that apply when this product is used for the specified purpose. If the machine is used for a purpose
that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration
of
safety in such operations is the responsibility
of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
o-3
4. LOCATION OF PLATES, TABLE TO ENTER

SERIAL NO. AND DISTRIBUTOR
4.1
Under
operators
4.2
SERIAL NO. PLATE POSITION
MACHINE
the front
seat.
ENGINE
of the console
box on the
seen
at the right side of blade back surface.
at the left side surface
of ripper
beam.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine
Engine
serial No.:
serial No.:
Distributor
name:
Phone:
Address:
Service
o-4
block, when
RIPPER SERIAL NO. PLATE POSITION

This is located
4.5
cylinder
BLADE SERIAL NO. PLATE POSITION

This is located
4.4
side of the
SERIAL NO. PLATE POSITION
On the upper left side of the engine

from the fan.
4.3
right
personnel
for your machine:
5. CONTENTS
............................................................................................................................................
1.
Foreword
2.
Safety
3.
Introduction
4.
Location
information
............................................................................................................................
........................................................................................................................................
of plates,
table to enter
serial No. and distributor
......................................................
o- 1
o- 2
0- 3
0- 4
SAFETY
6.
General
7.
..........................................................................................................
Precautions
during operation
Before starting engine .............................................................................................................
7.1
Operating machine ..................................................................................................................
7.2
7.3
7.4
7.5
precautions
.. .. . .. . . . .. . . . . . . .. . . .. . . . . . . . .. . . .. . . . . . . .. . . . . . . . . . . . .. .. . . . . . . .. .. . . . .. . .. . . . . . .. . . . . . . .. . .. . . . . . .. .. . . . . . . . .. . . . . . . ..
Transportation ..........................................................................................................................
Battery .......................................................................................................................................
Towing ......................................................................................................................................
I- 2
I- 9
I- 9
l-11
1-14
1-15
1-16
8.
...........................................................................................................
Precautions for maintenance
Before carrying out maintenance
..........................................................................................
8.1
................................................................................................................
During maintenance
8.2
1-17
I-17
1-19
9.
Position for attaching safety labels ................................................................................................

Position for attaching safety labels .......................................................................................
9.1
1-24
l-24
l-27
9.2
Content and use of warning plates .......................................................................................
OPERATION
10. General view ......................................................................................................................................
10.1
General view of machine.. ......................................................................................................
10.2
General view of controls and gauges ...................................................................................
.............................................................................................................
of components
11. Explanation
11.1 Front panel ..I . . . . .. . .. . .. . . . . . .. . . . .. . .. . . . . . . . . .. .. . . . . . . .. . . . .. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . .. ..~.....................
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
Switches ....................................................................................................................................
Control levers and pedals .......................................................................................................
Dust indicator ...........................................................................................................................
Power source ............................................................................................................................
Fuse box ...................................................................................................................................
Door-open lock (machines equipped with cab) ...................................................................
Sash glass intermediate lock (machines equipped with cab) ...........................................
Door pocket (machines equipped with cab) .........................................................................
Ashtray (machines equipped with cab) .................................................................................
Tool box.. ..................................................................................................................................
Using car stereo (machines equipped with cab and car stereo) ......................................
Handling air conditioner (machines equipped with cab) ....................................................
Handling heater (machines equipped with cab) ..................................................................
Handling accumulator .............................................................................................................
2- 2
2- 2
2- 3
2- 5
2- 5
2-21
2-24
2-31
2-31
2-31
2-33
2-33
2-33
2-33
2-34
2-35
2-40
2-44
2-45
o-5
2-46
. . . . . . . . .. .. .. . . . . .. .. .. . . . . . . .. . . . .. . .. . . . .. . .. . . . . . .. .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . .. . .. . . . . . . . . ._. .. . . . . . .. . .. .. . . . . . . ..................
12. Operation
Check before starting engine .................................................................................................
2-46
12.1
Starting engine.. .......................................................................................................................
2-61
12.2
Operations and checks after starting engine.. ......................................................................
2-65
12.3
Moving machine ......................................................................................................................
2-67
12.4
Shifting gear .............................................................................................................................
2-69
12.5
Shifting between forward and reverse.. ................................................................................
2-70
12.6
2-71
Steering machine .....................................................................................................................
12.7
Stopping machine ....................................................................................................................
2-73
12.8
Precautions for operation .......................................................................................................
2-74
12.9
2-77
12.10 Work possible using bulldozer ...............................................................................................
2-79
12.11 Ripper operation ......................................................................................................................
2-82
of work equipment .............................................................................................
12.12 Adjustment
2-84-l
12.13 Effective use of mode selection system ...............................................................................
2-85
12.14 Parking machine ......................................................................................................................
2-86
12.15 Check after finishing work.. ....................................................................................................
2-87
12.16 Stopping engine .......................................................................................................................
2-88
12.17 Check after stopping engine.. .................................................................................................
2-88
12.18 Locking ......................................................................................................................................
life ................................................................................................
2-89
12.19 Tips longer undercarriage
.. . . . . . . .. . .. . . . . . .. . .. .. . . . . . . .. . . . .. . . . . . .. . .. . . . . . . .. .. . .. . . . . . .. . .. .. . .. . .. .. . . . . . . . . . . . .. .. . . . . . . .. . . . . . . .. .. .. . . . . ...........
13. Transportation
Loading, unloading work ........................................................................................................
13.1
Precautions for loading ...........................................................................................................
13.2
Method of lifting machine ......................................................................................................
13.3
................................................................................................
Precautions for transportation
13.4
Removal of cab (machines equipped with cab). ..................................................................
13.5
Installation of cab (machines equipped with cab) ...............................................................
13.6
2-91
2-91
2-92
2-92
2-93
2-93
2-94
....................................................................................................................
14. Cold weather operation
Precautions for low temperature
...........................................................................................
14.1
After completion
of work ........................................................................................................
14.2
After cold weather ...................................................................................................................
14.3
2-95
15. Long-term storage .............................................................................................................................

15.1
Before storage ..........................................................................................................................
15.2
During storage .........................................................................................................................
15.3
After storage .............................................................................................................................
2-98
2-98
2-98
2-99
.................................................................................................................................
16. Troubleshooting
16.1
After running out of fuel .........................................................................................................
16.2
Method of towing machine ....................................................................................................
16.3
If battery is discharged ...........................................................................................................
16.4
Other trouble ............................................................................................................................
16.5
If mode selection system flashes ..........................................................................................
O-6
2-95
2-97
2-97
2-100
2-100
2-100
2-100
2-103
2-107
MAINTENANCE
17. Guides
to maintenance
. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . . . .. . . .. . . . . . . .. .. . .. . . . . . .. . .. . . . . . . .. .. . . . . . . .. .. . . . . . . .. . .. .. . . . .. . . . . . . . . . .. . . . . .. .
3- 2
18. Outlines of service ............................................................................................................................

18.1
Outline of oil, fuel, coolant.. ...................................................................................................
18.2
Relating to electric system .....................................................................................................
3- 5
3- 5
3- 7
19. Wear
3- 8
parts list ...................................................................................................................................
20. Use of fuel, coolant
and lubricants
according
to ambient
temperature
...................................
21. Standard tightening

torques for bolts and nuts ...........................................................................
21.1
Introduction
of necessary tools.. ............................................................................................
21.2
Torque list .................................................................................................................................
22. Periodic
replacement
of safety
parts
3-14
3-14
3-15
.. .. .. . . . . . . . .. . . . .. . . . . . . .. . .. .. . . . . . .. . .. . . . . . . .. .. . . . .. . . . .. . . . . . .. . . .. . . . . . ..
3-16
.. . . . . . . .. .. .. . . . . . .. . . .. . . . . . . . . . . . . .. . .. . . . . . .. . . . . . . . .. . .. .. . .. . . . . . .. . . . . . . .. . . .. . . . . . . . .. . . . . . . . . .. .. . .
3-21
24. Service Procedure . .. . .. . . . . . . . . .. .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . .. .. . . . . . . . . . .. .. . .. . . . . . .. .. . . . . . . . . . .. . . . . . . . . . .. .. . . . .. .. . .. . . . . . ......

24.1
Initial 250 hours service . .. . . . . . . . . . .. .. . .. . . . . . . . .. . .. . . . .. . . . . . .. . . . . . . .. . .. . . . . . . . . .. .. . . . . . . . . . . . .. . . . . . . .. . .. . . . . . . . .. . .. . . . .
24.2
When required . . . . .. . . . . . .. . . . . . . . .. . . .. . . . .. . . . . . . .. . .. .. . . . . . . .. . .. . . . . . .. .. . .. . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .. . . .. . . . . . . .. . . . . . . . . .. .
24.3
Check before starting .. . . . . . . .. .. .. . . . . . .. . . .. . . . .. . . . . . . .. .. . .. . . . . . .. . .. .. . . . .. .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . .. .. .. . . . . .. .. . .. .
24.4
Every 250 hours service . . .. . . .. .. . . . . . . . .. .. . . . . . . . . . . . .. .. . .. . . . . . .. . .. . . . . . .. . . . .. . . . . . . .. . .. . . . . . . .. . . .. . . . . . . .. . . . . . . .. . . . .. .
24.5
Every 500 hours service . .. . . .. . . . . . . . . . .. . .. . . . . . . . . . . .. . .. . .. . . . . . .. . .. . . . . . .. . . . . . . . . . .. .. . .. . . . . . . . .. . . . . . .. . . .. . . . . . . .. .. .. . .
24.6
Every 1000 hours service . . .. .. . . . . . . . .. . . .. . . . .. . . . . . . .. . . . .. . . . . . .. . . . .. . . . .. . .. . . . . . . . . .. .. . .. . . . . . . . .. . . . . . . . . . . .. . . . . . .. . .. .
24.7
Every 2000 hours service .. .. . . . . . . . . . .. . . . . . .. . . . .. . . .. . . . . . . . .. .. . . . . . . . . .. .. . . . . . . . . .. . .. . . . . . . . .. . . .. . . . . . . .. .. . . . . . . . . .. . .. .
24.8
Every 4000 hours service . . . . . . . .. . .. .. . . . . . . .. .. . .. . . . . . . . . . .. . . .. . .. . . . .. . . . . . .. . . . .. . . . . . . .. .. . .. . . . . . . . . .. . .. . . . .. . .. .. . . . . . .
3-25
3-25
3-26
3-48
3-57
3-65
3-69
3-73
3-78
23. Maintenance
schedule
chart
critical
3-10
SPECIFICATIONS
25. Specifications
. . . . . .. . . . . . . . .. . . . .. . .. . . . . . . .. . . . . . . . . . . .. .. . . . . . . .. . .. .. .. . . . . . . . . . . . .. . . . . . .. . . .. . . . . . . . . . . .. . . . . . . . .. .. . . . . . . . . .. .. .............
4- 2
o-7
OPTIONS,
ATiACHMENTS
..........................................................................................................................
26. General precautions
26.1
Precautions related to safety ..................................................................................................
5- 2
5 2
27. Using seat belt ..................................................................................................................................

manner.. ...................................................
27.1
Fasten the belt and remove it in the following
5- 3
5- 3
28. Selection of track shoe .....................................................................................................................

28.1
Selection of track shoe ............................................................................................................
5- 4
5- 4
29. Procedure for selecting ripper point.. ..............................................................................................

29.1
Procedure for selecting ripper point.. ....................................................................................
5- 5
5- 5
30. Handling cap with lock ......................................................................................................................

30.1
Opening and closing lockable cap.. .......................................................................................
5- 6
5- 6
31. Effective method of operation for dual tilt.. ...................................................................................

31 .I
Blade condition ........................................................................................................................
31.2
Dozing work ..............................................................................................................................
31.3
Leveling (spreading) operations .............................................................................................
31.4
Ditching operations .................................................................................................................
31.5
Boulder raising operations .....................................................................................................
31.6
Side cutting operations ...........................................................................................................
31.7
Horizontal dozing operations from side slope (rough ground). ........................................
5- 7
5- 7
5- 8
5-11
5-11
5-11
5-11
5-12
O-8
SAFETY
WARNING
Read and follow all safety precautions.

result in serious injury or death.
This safety section also contains
ment and attachments.
Failure
precautions
to do so may
for optional
equip-
l-l
A E~.M;;wJ~;~
Fo;eeasons
qf safety,
y precautions.
6. GENERAL PRECAUTIONS
SAFETY
RULES
ONLY trained
Follow all safety rules, precautions

on the machine.
When working with another operator or a person

understand all hand signals that are to be used.
SAFETY
always
and authorized
personnel
can operate
and instructions
and maintain
when
operating
on worksite
the machine.
or performing
maintenance
traffic duty, be sure all personnel
FEATURES
Be sure all guards and covers are in their proper position.

damaged.
Proper position + See 12.1.1 WALK-AROUND
CHECK.
Use safety features
CLOTHING
use of safety features
AND
and covers
repaired
if
such as the safety lock and seat belts properly.
NEVER remove any safety features. ALWAYS keep them

Safety lever + See 12.10 PARKING MACHINE.
Seat belts + See 27. USING SEAT BELT.
Improper
Have guards
PERSONAL
could result in serious
PROTECTIVE
in good operating
bodily
condition.
injury or death.
ITEMS
Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts
and cause serious injury or death. Also, do not wear oily clothes because they are flammable.
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 scattering
metal chips or minute materials-this
is so particularly when driving pins with a hammer and when
cleaning the air cleaner element with compressed
air.
Check also that there is no one near the machine.
Cleaning of air cleaner element + See 24.2 WHEN REQUIRED in service procedure.
A0055010
1-2
WARNING: Failure to follow these safety precautions may lead

to a serious accident.
UNAUTHOW
l
Any modification
Before making a modification,

consult your Komatsu distributor. Komatsu
for any injury or damage caused by any unauthorized
modification.
-I
made without
authorization
from
Komatsu
can create
hazards.
will not be responsible
STANDIN-
To avoid hitting unlocked
control
levers, before standing
Move joystick to neutral
and move SAFETY
Lower work
position.
to ground
Sudden
equipment
and unwanted
machine
LEVER (located
and move
movement
up from operators
SAFETY
left of seat) to LOCK position.
LEVER (located
can cause serious
seat, do the following:
right of seat) to LOCK
injury or death.
1-3
NEVER jump on or off the machine. NEVER get on or off a moving machine.
When mounting and dismounting, face the machine and use the handholds and steps. Maintain
three-point contact to be sure that you do not fall from the machine.
Do not hold any control levers when getting on or off the machine.
Repair any damaged handhold or step, and tighten any loose bolts. Handholds and steps must
be free of oil, grease and excessive dirt.
When mounting or dismounting,
use the points marked with arrows in the diagram below.
Use the parts marked by arrow A in the diagram below when getting on or off machine.
Never use the parts marked by arrow I3 when getting on or off the machine.
Use them only when moving along the top of the track or when checking or carrying out
maintenance inside the side cover, or when filling the tank with oil.
AE210270
l-4
nE207660
A WARNING: Failure to follow these safety precautions may lead

FIRE PREVENTION FOR FUEL AND OIL

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly
FLAMMABLE
and can be
HAZARDOUS.
Keep a flame away from flammable
fluids.
Stop the engine and do not smoke when refueling.
Tighten all fuel and oil caps securely.
Refueling and oiling should be made in well ventilated areas.
Keep oil and fuel in the determined
place and do not allow unauthorized
persons to enter.
-I
BURN HAZARD PREVENTION
If the coolant, engine oil, power train oil or hydraulic oil is hot, use a heavy cloth, gloves,
clothing and safety glasses or goggles before checking or touching.
To prevent hot water from spurting out:

1) Turn engine off.
2) Allow water to cool.
3) Slowly loosen cap to relieve pressure
before
removing.
To prevent hot oil from spurting out:

1) Turn engine off.
2) Allow oil to cool.
3) Slowly loosen cap to relieve pressure
before
removing.
heavy
A0055050
l-5
~~~i~W~e
ASBESTOS DUST HAZARD PREVENTION
Asbestos
If you handle materials containing asbestos fibers, follow these guidelines

1) NEVER use compressed
air for cleaning.
2) Use water for cleaning to minimize dust cloud.
3) Operate the machine with the wind to your back, whenever
possible.
4)
dust can be HAZARDOUS
Fo;eeasons of safety, always

y precautrons.
Use an approved
respirator
CRUSHING OR CUlTlNG
l
to your health
if it is inhaled.
as given below:
if necessary.
PREVENTION
Do not enter, or put your hand or arm or any other part of your body between movable parts such
as between the work equipment
and cylinders, or between the machine and the blade or ripper
or any other attachment.
If the work equipment is operated, the clearance will change and this may lead to serious damage
or personal injury.
A0055230
FIRE EXTlNGUlSHER
AND FIRST AID KIT
Be sure fire extinguishers
Know where
Know what to do in the event of a fire.
Be sure you know the phone
have been provided
and know how to use them.
a first aid kit is located.
numbers
of persons
you should
contact
AE104200
l-6
in case of an emergency.
A0055070

Do not operate
machine
with ROPS removed
if equipped.
The ROPS is installed to protect the operator if the machine should overturn. It is designed
only to take the load when the machine overturns, but also to absorb the impact energy.
not
The Komatsu ROPS fulfills all worldwide

regulations
and standards,
but if any unauthorized
modification
is carried out on it, or if it is damaged when the machine overturns, its strength will
be reduced and it will not be able to provide its original capacity. It will be able to provide this
capacity only if modifications
and repairs are carried out in the specified way.
When
carrying
out modification
or repairs,
always
consult
your Komatsu
distributor
Even when the ROPS is installed, if you do not fasten your seat belt securely,
your properly. Always fasten your seat belt when operating the machine.
first.
it cannot
protect
PRECAUTIONS FOR AlTACHMENTS

l
When installing and using an optional attachment,

read the instruction
and the information
related to attachments
in this manual.
Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of
unauthorized attachments could create a safety problem and adversely affect the proper operation
and useful life of the machine.
Any injuries, accidents, product failures

not be the responsibility
of Komatsu.
resulting
manual
from the use of unauthorized
for the attachment
attachments
will
l-7
;;:.:c;1ze
;;;ereasons
cjf safety, always
ty precautrons.
MACHINES WITH ACCUMULATOR

On machines equipped with an accumulator,
for a short time after the engine is stopped, if the
work equipment control lever is moved to the LOWER position, the work equipment will move down
under its own weight.
After stopping the engine, always place the safety lock lever in the LOCK position.
When releasing the pressure inside the work equipment
circuit on machines equipped
accumulator,
follow the procedure given in the inspection and maintenance
section.
Method of releasing pressure *
with an
See 11.16 HANDLING ACCUMULATOR.
The accumulator
is filled with high-pressure
nitrogen gas, and it is extremely dangerous if it is
handled in the wrong way. Always observe the following precautions.
l Never make any hole in the accumulator
or expose it to flame or fire.
l Do not weld any boss to the accumulator.
l When carrying
out disassembly
or maintenance
of the accumulator,
or when disposing of the
accumulator,
it is necessary to release the gas from the accumulator.
A special air bleed valve is
necessary for this operation, so please contact your Komatsu distributor.
Gas in accumulator + See 11.16 HANDLING ACCUMULATOR.
l-8
7. PRECAUTIONS
OPERATION
7.1
BEFORE STARTING
DURING
WARNING: Failure to follow these safety precautions

may lead to a serious accident.
ENGINE
Before starting the engine, thoroughly check the area for any
unusual conditions that could be dangerous.
Before starting the engine, examine the terrain and soil conditions of the worksite. Determine the best and safest method
of operation.
If you need to operate on a street, protect pedestrians and cars
by designating a person for worksite traffic duty or by installing fences around the worksite.
If water lines, gas lines, and high-voltage
electrical lines may
be buried under the worksite, contact each utility and identify
their locations. Be careful not to sever or cut any of these lines.
Check the depth and flow of water before operating in water
or crossing a river. NEVER be in water which is in excess of
the permissible water depth.
Permissible water depth --) See 12.9.1 PERMISSIBLE WATER
DEPTH.
FIRE PREVENTION
Thoroughly
remove wood chips, leaves, paper and other flammable
engine compartment.
They could cause a fire.
Check fuel, lubrication, and hydraulic systems
excess oil, fuel or other flammable
fluids.
Check point -+ See 12.1.1 WALK-AROUND

Be sure a fire extinguisher
is present
things
accumulated
for leaks. Have any leaks repaired.
Wipe
on the
up any
CHECK.
and working.
I-S
A ~~J~~HJize Ps;;ereasons of safety, always

ty precautrons.
7. PRECAUTIONS DURING OPERATION
IN OPERATORS CAB
Do not leave tools or spare parts lying around in the operators compartment.
or break the control levers on switches.
Keep tools in the tool box on the inside at the front of the right fender.
They may damage
Keep the cab floor, controls,
and excess dirt.
steps and handholds
free of oil, grease,
snow,
Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged
Always use seat belts when operating your machine.
VENTILATION
l
parts.
FOR ENCLOSED AREAS
If it is necessary to start the engine within

fumes from the engine can KILL.
an enclosed
area, provide adequate
ventilation.
Exhaust
A0055060
PRECAUTIONS FOR MIRRORS, WINDOWS

all dirt from the surface
AND LIGHTS
Remove
of the windows
and lights to ensure that you can see well.
Adjust the rear view mirror so that you can see clearly from the operators seat, and always
the surface of the mirror clean. If any glass is broken, replace it with a new part.
Check that the head lamps and rear lamps are installed
also that they light up properly.
PRECAUTIONS FOR SLIDING GLASS INTERMEDIATE
to match the operating
conditions.
keep
Check
LOCK
The sliding glass intermediate

lock is to prevent rattling of the glass.
Even when the lock is used, the glass may move because of the
shock when starting or stopping suddenly.
Do not put your head or hands out of the window during operations.
7690
-j
CHECK THOROUGHLY
Always
I-IO
BEFORE STARTING
carry out all checks before
starting.
A ~~f?~Ll~G; Faail;;o
follow these safety precautions may lead

7.2
OPERATING
MACHINE
Walk around your machine

might be in the way.
NEVER start the engine
When
starting
if a warning
the engine,
Start and operate
again just before
anyone
For machines
equipped
PRECAUTIONS
WHE
it, checking
tag has been attached
for people
and objects that
to the control.
sound the horn as an alert.
the machine
Do not allow
mounting
only while
seated.
other than the operator

with
backup alarm,
to ride in the cab or on the machine

check that the warning
device operates
body.
correctly.
Before moving machine or its attachments:

Honk horn to alert people nearby.
Be sure no one is around
Use spotter
if necessary,
When operating
worksite traffic.
Prevent
Follow
people
above
machine,
particularly
particularly
if you are moving
in areas that may be hazardous
from entering
even if equipped
behind
the line of travel

with backup
machine.
in reverse.
or have poor visibility,
designate
a person to direct
of the machine.
alarm
and mirrors.
A0055080
I-11
TRAVELING
Traveling
slipping.
ON SLOPES
on hills, banks or slopes that are steep could result in the machine tipping over or
On hills, banks or slopes, carry the work equipment closer to the ground, approximately 20 to 30
cm (8 to 12 in) above the ground. In case of emergency, quickly lower the work equipment to the
ground to help the machine stop and prevent it from tipping over.
Do not change direction on slopes. Avoid sideways travel whenever possible: rather travel up and
down the slopes.
Do not travel up and down on grass, fallen leaves, and wet steel plates. These materials may allow
the machine to slip, if it is traveling sideways. Keep travel speed very low.
When traveling downhill, drive slowly and use the engine as a brake.
When traveling downhill with the machine being pushed by its own weight, the machine may steer
in the opposite direction, so be careful when steering.
Reverse steering when traveling downhill + See 12.7.2 TURNING WHILE DESCENDING A
SLOPE.
INCORRECT
CORRECT
AD051690
Turn ON the head lamps and rear lamp, when working at night or at dark sites. Provide additional
lights for the worksite if necessary.
If visibility is diminished by fog, snow or rain, stop operation. Wait until there is adequate visibility
for safe operation.
Snow-covered and frozen ground may allow the machine to slip sideways, even if the grade is
not steep. Slow down the machine when traveling on such ground. Avoid rapid starts, stops, and
steering.
In snow removal work, pay special attention to the edge of the road and to objects under the snow.
1-12
;;F!$J;;;;
F~ZI;I~O
follow these safety precautions may lead

Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these
areas collapse, your machine could fall or tip over and result in serious injury or death. Remember
that the soil after heavy rain or blasting is weakened
in these areas.
Earth laid on the ground and the soil near ditches are loose. They can collapse
or vibration of your machine.
Install the HEAD GUARD
dirt.
or FOPS if working
in areas where
When working in places where there is danger

over, install ROPS and a seat belt.
of falling
there is danger
rocks or danger
under the weight
of falling
rocks and
of the machine
turning
PARKING1
Park on level ground whenever possible. If not possible,
ground and thrust the edge of the blade in the ground.
block the tracks, lower the blade to the
Thrust
the edge
AE20770B
When parking on public roads, provide fences and signs, such as flags or lights, on the machine
to warn passersby to be careful. Be sure that the machine, flags or lights do not obstruct traffic.
Parking procedure + See 12.14 PARKING MACHINE.
Before leaving the machine, lower the work equipment to the ground, move the SAFETY LEVER
to LOCK position, stop the engine, and lock all the doors, windows, and covers and remove the
key(s).
Work equipment
posture + See 12.14
Locks + See 12.18 LOCKING.
PARKING
MACHINE.
1-13
a
7.3
4
~;~;;$iseFc;ereasons
of safety, always
tv orecautrons.
TRANSPORTATION
LOADING AND UNLOADING
Loading
SHOULD
and unloading
BE USED.
the
machine
Perform loading and unloading

of a road.
ALWAYS block the wheels
loading and unloading.
always
involves
potential
on firm, level ground only. Maintain
of the hauling
ALWAYS use ramps of adequate

a safe loading slope.
strength.
vehicle
and place
hazards.
EXTREME
a safe distance from the edge
blocks
under
both
and fastened,
on the ramps.
block the machine
before
and that the two sides are at the same
Be sure the ramp surface is clean and free of grease, oil, ice and loose materials.
the machine tracks.
After loading,
ramps
Be sure the ramps are wide and long enough to provide
Be sure that the ramps are securely positioned

level as one another.
NEVER correct your steering

again.
CAUTION
If necessary,
Remove dirt from
drive away from the ramps and climb
tracks and secure the machine
with tie-downs.
Loading and unloading + See 13. TANSPORTATION.

Tie-downs + See 13. TRANSPORTATION.
CORRECT
Distance
between
ramps
AD052900
SHIPPING
l
When shipping the machine on a hauling vehicle, obey all state and local laws governing
weight, width, and length of a load. Also obey all applicable traffic regulations.
Determine
1-14
the shipping
route while taking into account the width,
height and weight
the
of the load.

7.4
BATTERY
Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing.
If you spill acid on yourself, immediately
flush the area with water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them
immediately
with large quantities of water and see a doctor at once.
If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil.
Call a doctor or poison prevention center immediately.
When working with batteries. ALWAYS wear safety glasses or goggles.
Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a
small spark or flame.
Before working with batteries, stop the engine and turn the starting switch to the OFF position.
Avoid short-circuiting
the battery terminals through accidental contact with metallic objects, such
as tools, across the terminals.
Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an
explosion.
Tighten the battery cap.
A0055110
A0055100
STARTING
ALWAYS
When
WITH
wear
starting
BOOSTER
CABLES
safety glasses
from another
or goggles
machine,
when
starting
the machine
do not allow the two machines
Be sure to connect the positive (+I cable first when installing

ground or negative (4 cable first when removing them.
Connect
l
the batteries
in parallel:
positive
to positive
When connecting the ground cable to the frame

it as far as possible from the battery.
Starting
with
booster
of the machine
cables.
to touch.
the booster
and negative
cables + See 16.4 IF BATTERY
with booster
cables.
Disconnect
the
to negative.
to be started,
be sure to connect
IS DISCHARGED.
INCORRECT
A0067320
g
7.5
~~y~;~~;e~aa;ereasons
of safety, always
ty precautrons.
TOWING
_i FIT WIRE TO HOOK WHEN TOWING
injury or death could result if a disabled

If your machine
capacity.
is towed
by another
machine
machine,
is towed
ALWAYS
incorrectly.
use a wire rope with a sufficient
If your machine is towed by another machine, stop the engine

contact your Komatsu distributor to have the brake released.
NEVER allow
a disabled
machine
Do not use a kinked or frayed

Do not straddle
the towing
to be towed
wire
cable or wire rope.
Take up the slack in the wire
connection
enter the area between
of the equipment
being towed
the towing
in a straight
rope and tow the machine.
up, use the towing
hook.
If the machine is stuck in sandy soil, dig out the soil around the towing
hook to pull the machine out.
Permissible load for towin,g hook: 48500 kg (475623 N)
AE207710
1-16
Please
rope.
Set the towing machine and the towing

line when connecting it.
lifting the machine
the brake.
on a slope.
When connecting
up a towing machine, do not let anyone
machine and the equipment
being towed.
When
and release
towing
hook, then use the towing
8. PRECAUTIONS
MAINTENANCE
8.1
FOR
BEFORE CARRYING
If others start the engine
you could suffer serious

OUT MAINTENANCE
or operate the controls while you are performing

injury or death.
service or lubrication,
ALWAYS attach the WARNING

TAG to the control lever in the operators cab to alert others that
you are working on the machine. Attach additional warning tags around the machine, if necessary.
These tags are available
from your Komatsu
distributor.
Part No.
i
When
this
N+~~;~
plate IS not being used

keep it in the storage compartment.
PROPER TOOLS
l
Enalish
09963 - 03000
German
09963 - 02000
Spanish
09963 - 01000
French
09963 - 05000
Italian
09963 - 06000
II\\
\\
AE207730
Use only tools suited to the task. Using damaged,

low quality,
cause personal injury.
Tools + See 21.1 INTRODUCTION OF NECESSARY TOOLS.
faulty,
or makeshift
tools could
A0055120
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

l
Replace the following

Fuel system:
Hydraulic system:
fire-related
components
periodically:
Fuel hose, spilling hose, and fuel tube cap
Pump outlet hoses
Replace these components

periodically with new ones, regardless
to be defective. These components
deteriorate
over time.
Replace or repair any such components

the time specified.
of whether
or not they appear
if any defect is found, even though they have not reached
Replacement of safety critical components
See 22. PERIODIC REPLACEMENT OF SAFETY

CRITICAL PARTS.
1-17
a
8. PRECAUTIONS FOR MAINTENANCE
E;y;:T;f;eE;eeasons
of safety, always
y precautrons.
STOP THE ENGINE BEFORE CARRYING

OUT INSPECTION AND MAINTENANCE
Always stop the machine
and maintenance.
on firm flat ground
and stop the engine
before carrying
If it is necessary to run the engine when carrying out maintenance,

inside of the radiator, place the safety lock lever at the LOCK position
with two workers.
out inspection
such as when cleaning the

and carry out the operation
One worker should sit in the operators seat so that he can stop the engine immediately
if
necessary. He should also be extremely careful not to touch any lever by mistake. Touch the levers
only when they have to be operated.
The worker carrying out the maintenance
in the moving parts.
If maintenance
blocks.
is carried
should be extremely
out with the work
equipment
raised,
careful
always
not to touch or get caught
support
it securely
with
OFF
ON
-START
AD051781
1-18
E;P$J;V:s
,;;;;no
follow
these safety precautions may lead

8.2
l
DURING
MAINTENANCE
Only authorized
personnel can service and repair the machine. Extra precaution should be used when grinding, weiding, and using a sledge-hammer.
Keep a safe distance

17A-98.11530
-/
ATTACHMENTS
l
Place attachments that have been removed from the machine

in a safe place so that they do not fall. If they fall on you or
others, serious injury could result.
A0055130
WORK
UNDER
THE MACHINE
Always lower all movable work equipment

to their lowest position before performing
under the machine.
Always
Never work
supported.
I
I
block the tracks of the machine

under
KEEP THE MACHINE
the
machine
if the
to the ground or
service or repairs
securely.
machine
is poorly
A0055140
CLEAN
Spilled oil or grease, or scattered tools or broken pieces are

dangerous because they may cause you to slip or trip.
Always keep your machine clean and tidy.
If water gets into the electrical system, there is danger that the
machine may not move or may move unexpectedly.
Do not use water or steam to clean the sensors, monitors,
controllers, connectors, or the inside of the operators compartment.
A00551
50
1-19
E;.;;;?e
1 RULES TO FOLLOW WHEN ADDING FUEL OR OIL

Spilled
fuel and oil may cause you to slip, so always
Always
tighten
Never
1
wipe
it up immediately.
the cap of the fuel and oil fillers securely.
use fuel for washing
any parts.
A0055040
A0055030
A0055020
Fc;e reasons cf safety, always

ty precautrons.
RADIATOR WATER LEVEL 1

l
When checking the water level, stop the engine and wait for the engine and radiator to cool down
first.
If removing
When checking fuel, oil, coolant, or battery electrolyte,

always use lighting
specifications.
If such lighting equipment
is not used, there is danger of explosion.
the radiator
USE OF LIGHTING
cap, turn it slowly
to release the internal
pressure.
1
with
antiexplosion
A0055160
I-20

PRECAUTIONS
l
WITH
BATTERY
When repairing the electrical system or when carrying out electrical

@ terminal of the battery to stop the flow of current.
welding,
remove the negative
A0055170
Do not bend high-pressure

hoses or hit them with hard objects.
piping, tubes or hoses. They may burst during use.
Always
Do not use any bent or cracked
repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
Avoid torching, soldering, or welding on pipes, tubes and equipment

that contain fuel or oils.
If heated, they can generate flammable
fumes or mist and could cause a fire or explosion.
PRECAUTIONS
Do not forget
WITH
that the work equipment
circuits are always
Do not add oil, drain oil, or carry out maintenance

internal pressure.
under
or inspection
pressure.
before completely
releasing
the
If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure
oil hits your skin or enters your eyes. Always wear safety glasses and thick gloves, and use a piece
of cardboard or a sheet of wood to check for oil leakage.
If you are hit by a jet of high-pressure
oil, consult
A0055180
a doctor
immediately
for medical
attention.
A0055190
1-21
a
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

HIGH TEMPERATURE
l
WARNING: For reasons of safety, always

follow these safety precautions.
AT
OR HIGH PRESSURE
Immediately
after stopping operations, the engine cooling water and oil at all parts is at high
temperature
and under high pressure.
In this condition, if the cap is removed, or the oil or water are drained, or the filters are replaced,
this may result in burns or other injury. Wait for the temperature
to go down, then carry out the
inspection and maintenance
in accordance with the procedures given in this manual.
Clean inside or cooling
Check cooling
water
system
+ See 24.2 WHEN
level, lubricating
oil level, hydraulic oil level

+ See 24.3 CHECK BEFORE STARTING.
Checking
final drive case + See 24.4 PERIODIC
Changing
oil, replacing
filters
REQUIRED.
MAINTENANCE.
+ See 24.5 - 7 PERIODIC
MAINTENANCE.
PRECAUTIONS
WHEN 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 adjustments,
grease fitting may fly out and cause damage or personal injury.
l When loosening
the grease drain plug, never loosen it more than one turn.
l
Never put your face, hands, feet, or any other part of your body directly
drain plug or valve.
Adjusting
-I
ROTATING
track tension
FAN AND
-+ See 24.2 WHEN
BELT
rotating
the plug or
in front of any grease
REQUIRED.
Keep away from
parts and be careful
not to let anything
get caught
in them.
If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying, so never
touch any rotating parts.
A0055210
l-22

WASTE
Never
Aiways
MATERIALS
dump waste
1
oil in a sewer
put oil drained
system,
from your machine
rivers, etc.
in containers.
Obey appropriate
laws and regulations when
coolant, solvent, filters, batteries, and others.
disposing
Never drain oil directly

of harmful
objects
on the ground.
such as oil, fuel,
INCORRECT
A0055220
l-23
9. POSITION FOR ATTACHING
SAFETY LABELS
Always keep these labels clean. If they are lost or damage,

attaching them again or replace them with a new label.
There are other labels in addition to the safety labels listed as
follows, so handle them in the same way.
Safety labels may be available in languages other than English.
To find out what labels are available, contact your Komatsu
distributor.
9.1
POSITION
FOR ATTACHING
SAFETY
LABELS
Accumula
View
Y
View
l-24
db1
Of
P portion
9. POSITION FOR ATTACHING SAFETY LABELS AND STORAGE OF OPERATION & MAINTENANCE MANUAL
1.
Warnings before operating machine

(14X-98-l 1580)
3.
Warnings for leaving operators seat

(14X-98-l 1541)
g, WARNING
Improper
tenance
operation
To avoid hitting unlocked

operation levers, before standing up from operators seat, do
the following:
Move steering and directional lever neutral and
move SAFETY LOCK LEVER
(located left of seat) to LOCK
position.
Lower equipment
to ground
and move SAFETY LOCK
LEVER (located right of seat)
to LOCK position.
and main-
can cause serious
injury or death.
Read manual
operation
Follow
and labels before
and maintenance.
instructions
ings in manual
and warn-
and in labels on
machine.
Keep manual
in machine
cab
near operator.
Contact
Komatsu
for a replacement
Sudden and unwanted

machine
movement
can cause serious
injury or death.
distributor
manual.
14X-98-11580 -
2.
Warnings before moving in reverse

(14X-98-l 1590)
WARNING
4.
14X-98-11541 -
Warnings for hot water hazard

(14X-98-11531)
Hot water
Before moving machine or its

attachments:
l Honk horn to alert people
nearby.
l Be sure no one is on machine
area.
0 Use spotter if necessary,
particularly if you are moving
in reverse.
Follow above even if equipped
with back-up alarm and mirrors.
14X-98-11590
hazard.
To prevent hot water from

spurting out:
l Turn engine off.
l Allow water to cool.
0 Slowly loosen cap to relieve
pressure before removing.
WARNING
14X-98-11531 -
l-25
9. POSITION
FOR ATTACHING
Cautions for opening

(09653-03000)
SAFETY
LABELS
cap of hydraulic
tank
7.
Warning
(14X-98-l
for handling
1390)
accumulator
8.
Warning for use of seat belt

(195-98-12940)
1. ALWAYS STOP ENGINE WHEN

REMOVING CAP.
2. DO NOT LOOSEN CAP WHEN 01
TEMPERATURE IS HIGH.
IF LOOSENED, OIL MAY GUSH
_I *_
UUI.
3. SLOWLY OPEN HYDRAULIC OIL

TANK CAP AND RELEASE
INTERNAL PRESSURE COMPLETELY.
4. DO NOT OPEN DRAIN PLUG
;;EN
OIL TEMPERATURE IS
I
09653-03000J
Warnings for adjusting

(195-98-22931)
track tension
CAUTION
ALWAYS USE SEAT BELT WHEN OP.
ERATING MACHINE.
ALWAYS CHECK CONDITION
OF THE
SEAT
BELT,
THE
CONNECTING
BRACKETS
AND THE TIGHTENING
Compressed spring, plug and grease are under hazardous
high pressure and can cause serious injury or death.
1. When adjusting track tension, only turn plug @ ONE TURN.
Turning plug further could cause plug and grease to fly off
and hurt you. See manual for adjustment instructions.
2. When loosening track shoe, if it does not loosen after turning
plug @ ONE TURN, ask Komatsu dealer or distributor to
disassemble.
3. Never disassemble bolts @. Idler and yoke @ may suddenly
release and hit you. Ask Komatsu dealer or distributor to
disassemble.
BOLTS.
ADJUST
SEAT TO ALLOW
FULL
BRAKE PEDAL TRAVEL WITH OPERA.
TORS BACK AGAINST SEAT BACK.
AFTER ADJUSTING
THE HEIGHT
FORE AND AFT POSITIONS OF THE
SEAT, TIGHTEN THE TETHER BELl
BEFORE SITTING IN THE SEAT.
195-98-12940
l-26
9. POSITION FOR ATTACHING SAFETY LABELS
9.
Warning for ROPS (for America

(09620-30201)
and Canada)
ROLL-OVERPROTECTIVESTRUCTURE(ROFS, CERTlFlCATlON
THISKOMATSU ROPS.MODEL&type No.lSERIALNo.IWHEN
INSTALLED IN ACCORDANCEWIT THE MANUFACTURES INSTALLATION INSTRUCTlONS ON A -1
FOR MAXIMUM PRIME MOVER
MASS NOT GREATERTHAN [
LBS,#9). IS CERTIFIEDTO
COMPLY WITH THE FOLLDWING REDUIREMENTS: a, IS0 3471 (ROPS) & IS0
3449 (FOPS, b) SAE J 0
& SAE J -
11
* Altering ROPS may weaken it. Consult Komatsu Distributor before

altering.
* ROPS may provide less protection if it has been structurally damaged or involved in roll-over.
* Always wear seat belt when moving.
Komatsu Ltd. Japan
9.
Z-3-6 Akasaka, Minato-ku, Tokyo, Japan
Warning for ROPS (except

(09620-30200)
KOMAdbU
America
09620-30201
and Canada)
ROLL-OVERPROTECTlM STRUCTVRE(ROPSI
TWEROLL-OVERPROTECTIVESTRUCTUREOF THIS MACHINE COMPLlESWlTH
THE FOLLOWINGSTANDARDS OR ,RECOMMENDED PRACTICES)
INTERNATIONALSTANDARD: IS0 34771IROPSI & IS0 3449 (FOPS.1
AMERICAN STANDARD: SAE J 0
& SAE J I]
MODEL n
- Altering ROPS may weaken it. Consult Komatsu Distributor before

altering.
- ROPS may provide less protection if it has been structurally damaged or involved in roll-over.
* Always wear seat belt when moving.
Komatsu Ltd. Japan
9.2
1.
Content
Z-3-6 Akasaka, Minato-ku, Tokyo, Japan
and use of warning
09620.30200
plates
Warning to prevent operation during maintenance

(09963-03000)
Hang this warning plate on the controls in the operators
partment.
com-
l-27
OPERATION
10. GENERAL VIEW
10.1
GENERAL
If directions
diagram below.
Machines
VIEW OF MACHINE
are indicated
equipped
in this section,
they
refer to the directions
shown
by the arrows
in the
with cab
Blade
lift
Cab
cylinder
Fuel
Track
tank
frame
Frame
Machines
equipped
with canopy
Track
shoe
AE207758
canooy
Left
Front
AE20776B
2-2
10.2
GENERAL
Machines
VIEW OF CONTROLS
equipped
with cab
Head
Air
or
Lock
IamP
conditioner
Heater
Panel
UD mode
switch
Toraue
IockuI)
switch
AND GAUGES
converter
pilot
IamD
\
Warning
Rear
lamp
lamp
switch
Starting
switch
panel
rake
Dedal
eration
Pedal
Blade
Fuel
control
Cigarette
control
control
I ever
lighter
Pin-Duller
switch
AE210288
Engine
water
Charge
IamD
Engine
oil
oressure
Safety lever
_
I
Parking lever
oil
Transmission
temDerature
Wiper
gauge
Service mater
drive pilot lamp
switch
Fue I
gauge
Radiator
level
Service
co.olant
check
lamn
Preheater
I amp
.--I
Engine
check
\Transm~ssron
temperature
caution
pilot
\
oil
lame
level
meter
Hydraulic
caution
oil
Iamp
oil
lamp
temDerature
AD210298
AE20'779B
2-3
10. GENERALVIEW
Machines equipped with canopy

Switch
Preheater
Rear
Head
Lock
IamD
UD mode
IamD
switch
Ioraue
IockuD
converter
D~lot
IamD
Warning
IamD
switc
Starting
switch
swi
Brake
JOvst
ick
Stee r ing,
gear
shift
Dedal
Deceleration
dl rect
lever
ional.
Blade
Fuel
control
control
lever
Horn
switch
Pin-Duller
AE210308
Engine
Charge
water
IamD
Engine
oii
Dressure
Parking lever
I amD
Transmission
temDerature
Engine
water
temDerature
caution
IamD
oil
gauge
Service mater
drive pilot lamp
Fuel
gauge
Radiator
Service
2-4
Transmission
temoerature
caution
lamD
CO
Engine
check
meter
oil
IamD
level
Hvdpauiic
caution
Oil
IamD
Oil
temDeratUre
brl,,n,09
11. EXPLANATION
OF COMPONENTS
The following
is an explanation
of the devices needed for
operating the machine.
To carry out suitable operations correctly and safely, it is important
to understand fully the methods of operating the equipment and the
meanings of the displays.
11 .I FRONT PANEL
D
A021031B
CHECK MONITOR GROUP (11.1.1)

(Check items before starting)
If there is any abnormality,
the appropriate
monitor lamp will
flash.
Check the location where the monitor lamp is flashing, and carry
out the checks before starting.
When the engine is started, these monitor lamps will go off even
if there are abnormalities.
NOTICE
When carrying out checks before starting, do not simply rely on
the monitor. Always refer to the periodic maintenance
items or 12.
OPERATION
to carry out the checks.
2-5
11. EXPLANATION OF COMPONENTS
@I CAUTION MONITOR
(Caution items)
GROUP
A
If any monitor
lamp flashes,
(11.1.2)
WARNING
repair
it immediately.
If the abnormality
occurs while the engine is running, the
appropriate
monitor lamp will flash to indicate the abnormality.
Even if the monitor lamp flashes, the machine can operate, but
it should be repaired as soon as possible.
@
CAUTION MONITOR
(Emergency caution
GROUP
items)
g
If any monitor
immediately.
lamp
(11.1.3)
WARNING
flashes,
stop
the
work,
and
repair
it
If any abnormality
occurs while the engine is running, the
appropriate monitor lamp will flash and the alarm buzzer will sound
intermittently
at the same time.
Even if the monitor lamp flashes, the machine can operate, but
it should be repaired as soon as possible.
@
METER GROUP (11.1.4)

This group consists of engine water temperature
train oil temperature
gauge, fuel gauge and service
SWITCH GROUP (11.1.5)
This group consists of starting switch,
mode switch and preheating switch.
gauge,
meter.
power
LAMP GROUP (11.1.6)

This group consists of warning
up pilot lamp.
lamp switches,
lock up
lamp and torque
converter
lock
Functional check of the machine monitor system

When the starting switch is turned ON before starting the engine,
the monitor lamps flash for 3 seconds, the warning lamp lights for
2 seconds, and the alarm buzzer sounds for 1 second.
l
If any monitor lamp does not light up, there is probably a broken
bulb or disconnection
in the monitor,
so ask your Komatsu
distributor to inspect it.
l
The monitor system cannot be checked for breakage until 30
seconds after the engine has been stopped.
2-6
11.1.1 A: CHECK MONITOR GROUP

(Check items before starting)
NOTICE
When carrying out checks before starting, do not simply rely on
the monitor. Always refer to the periodic maintenance
items or 12.
OPERATION
to carry out the checks.
Park the machine on level ground and check the monitor lamps.
Confirm that these monitor lamps light for about 3 seconds after
the starting switch is turned to ON. If any monitor lamp does not
light, ask your Komatsu distributor to inspect it.
A0210328
1.
RADIATOR COOLANT LEVEL MONITOR

This monitor indicates a low radiator coolant level.
If the monitor lamp flashes, check the coolant level and add
water as required.
I
AD207820
2.
ENGINE OIL LEVEL MONITOR

This monitor indicates a low oil level in the engine oil pan.
._
If the monitor lamp flashes, check the oil level in the engine oil
pan and add oil as required.
A0207830
2-7
11 .I.2 B: CAUTION MONITOR

(Caution items)
a
If this monitor
lamp flashes,
GROUP
WARNING
repair
it immediately.
NOTICE
AD21033B
1.
CHARGE
MONITOR
This monitor indicates an abnormality in the charging system

while the engine is running.
If the monitor lamp flashes, stop the engine and check the V-belt
tension. If any abnormality is found, see 16. TROUBLESHOOTING.
REMARK
This monitor lamp lights, when the starting switch is turned to

ON immediately after the engine is started or immediately before
the engine is stopped. It does not indicate an abnormality.
2-8
+
I
A0207850
11.1.3 C: CAUTION MONITOR GROUP

(Emergency caution items)
a
WARNING
If any monitor lamp flashes, stop the engine

idling speed, and repair it immediately.
or run it at a low
NOTICE
AD21034E
1.
ENGINE OIL PRESSURE MONITOR

This monitor indicates a low engine
If the monitor
lamp flashes, stop
immediately.
oil pressure.
the engine and
check
it
REMARK
This monitor lamp flashes and the alarm buzzer sounds, when
the starting switch is turned to ON immediately
after the engine is
started or immediately
before the engine is stopped. It does not
indicate an abnormality.
2-9
2.
RADIATOR COOLANT LEVEL MONITOR

This monitor indicates a low radiator coolant level.
When the monitor lamp flashes, stop the engine,
coolant level and add water as required.
check
the
3.
ENGINE COOLING WATER TEMPERATURE

MONITOR
This monitor indicates a rise in the cooling water temperature.
When the monitor lamp flashes, run the engine at the low idling
speed until the green range of the engine water temperature
gauge
lights.
I
4.
POWER TRAIN OIL TEMPERATURE

MONITOR
This monitor indicates a rise in the oil temperature
of the torque
converter outlet.
When the monitor lamp flashes, run the engine at the low idling
speed until the green range of the power train oil temperature
gauge
lights.
HYDRAULIC OIL TEMPERATURE

This monitor indicates a rise in
When the monitor lamp flashes,
engine at the low idling speed until
5.
2-10
MONITOR
the hydraulic oil temperature.
stop the machine and run the
oil temperature
falls.
I
A0207880
11.1.4 D: METER GROUP

NOTICE
While the engine is at rest, turn the starting switch ON to see
if meter lamps 0, @ and @ and the monitor lamp all come on. If
they do not light, ask your Komatsu distributor to inspect them.
d5
b4
\\
D
1.
ENGINE
COOLING
WATER
TEMPERATURE
GAUGE
This gauge indicates the temperature of the cooling water.

If the temperature is normal during operation, the green range will
light.
If the red range lights up during operation, move the fuel control
lever to lower the engine speed to approx. 3/4 of the full speed, and
run until the water temperature enters the green range.
If the engine cooling water temperature enters the red range,
and the engine water temperature monitor flashes and the alarm
buzzer sounds, stop the machine and run at low idling until the water
temperature enters the green range.
NOTICE
If the water temperature
gauge
check the radiator for clogging.
often
enters
the
H
Green
White
red range,
2-11
2.
POWER TRAIN OIL TEMPERATURE

GAUGE
This gauge indicates the oil temperature
of the torque converter
outlet. If the temperature
is normal during operation,
the green
range will light.
If the red range lights up during operation, move the fuel control
lever to lower the engine speed to approx. 3/4 of the full speed,
reduce the load and run until the oil temperature
enters the green
range.
If the power train oil temperature
enters the red range, and the
power train oil temperature
monitor flashes and the alarm buzzer
sounds, stop the machine
and run at low idling until the oil
temperature
enters the green range.
Red
Green
AD207938
NOTICE
If the power train oil temperature
gauge often enters the red
range, we recommend
you to lower the travel speed one range (for
example,
F2 + Fl) to reduce the load on the power train when
operating.
3.
FUEL GAUGE
This gauge indicates the amount of fuel in the fuel tank. If there
is enough fuel in the tank while the engine is running, the green
range lights. If the red range lights, there is less than 150 e(39.6 US
gal, 33 UK gal) of fuel in the tank.
When the red range lights, add fuel.
REMARK
The display
amount of fuel.
is not
directly
proportional
with
the
remaining
4.
SERVICE METER
This meter shows the total operation hours of the machine. The
service meter advances while the engine is running - even if the
machine is not traveling.
Set the periodic maintenance
intervals using this display.
When the engine is running, the green pilot lamp at the top of
the meters flashes to indicate that the meter is advancing.
Meter will advance by 1 for each hour of operation regardless of
the engine speed.
5. ENGINE PREHEATING
PILOT LAMP
This lamp indicators the engine preheating time when starting
the engine by operating APS (Automatic Priming System). When the
starting switch key is placed in ON, this lamp lights and goes out
after approx. 12 seconds, indicating that the preheating of the engine
has been completed.
2-12
AD104460
11.1.5 E: SWITCHES
(MACHINES
EQUIPPED WITH CAB)
AE210360
I
I.
STARTING SWITCH
This switch
OFF
is used to start the engine.
I
OFF
Key insertion-withdrawal
activate.
position.
None
of electrical
circuits
-
ON
Charging and electric
after starting.
START
AD051780
device
circuits
activate.
Keep key at ON
START
At this key position, the starting motor will crank the engine.
Immediately
after starting the engine, release the key which will
automatically
return to the ON position.
2-13
1I. EXPLANATION OF COMPONENTS
2.
FRONT LAMP, WORKING LAMP SWITCH

This lights up the front lamps, working lamps at the front of the
left and right fenders, and the panel lamp.
OFF position:
ON position:
OFF
ON
LJ
Lamps are out

Lamps light up
AD051790
3.
REAR LAMP SWITCH

This lights up the rear lamps.
OFF position:
ON position:
OFF
ON
LJ
Lamps are out

Lamps light up
AD051790
4.
PREHEATING SWITCH
OFF position:
ON position:
I, II position:
Preheating is not actuated

Automatic preheating is actuated
Preheating is not actuated. Normally do not turn the
key to these positions.
AE208940
CAUTION
When not using the APS, do not turn the switch to the ON
position. For details, see 12.2.2 STARTING IN COLD AREAS.
This is used when using the APS to start the engine in cold areas.
When the switch is turned to the ON position, electricity flows to the
glow plug and the intake air is heated. The preheating monitor on
the monitor panel lights up when the switch is turned ON.
Do not turn the switch to the ON position when not using the
APS.
A
2-14
A0207950
5.
LOCKUP MODE SWITCH
This is used when greater power is needed rather than larger

production (such as when dozing loose soil).
The system is switched between torque converter drive and
direct drive to match the load. When the switch is turned ON, the
torque converter lock-up pilot lamp lights up.
OFF position:
ON position:
Torque converter drive

Used when greater power is needed, rather than
larger production (such as when dozing loose soil).
The system is switched between torque converter
drive and direct drive to match the load.
OFF
ON
d/
ADO51790
2-l 5
11. EXPLANATION
OF COMPONENTS
11 .I.5 E: SWITCHES
(MACHINES
EQUIPPED WITH CANOPY)
AE210450
1.
STARTING SWITCH
This switch
OFF
is used to start the engine.

I
OFF
Key insertion-withdrawal
activate.
position.
None
of electrical
circuits
ON
Charging and electric
after starting.
device
circuits
activate.
Keep key at ON
START
At this key position, the starting motor will crank the engine,
Immediately
after starting the engine, release the key which will
automatically
return to the ON position.
2-16
2.
FRONT LAMP, WORKING LAMP SWITCH
This lights up the front lamps, working lamps at the front of the
left and right fenders, and the panel lamp.
OFF
ON
lJ
OFF position:
ON position:
Lamps are out

Lamps light up
A0051790
3.
REAR LAMP SWITCH

OFF position:
ON position:
OFF
ON
lJ
Lamps are out

Lamps light up
A0051790
4.
PREHEATING SWITCH
OFF position:
ON position:
I, II position:
Preheating is not actuated

Automatic
preheating is actuated
Preheating is not actuated. Normally
key to these positions.
ll
do not turn the
PIE208940
a
CAUTION
When not using the APS, do not turn the switch to the ON
position. For details, see 12.2.2 STARTING IN COLD AREAS.
This is used when using the APS to start the engine in cold areas.
When the switch is turned to the ON position, electricity flows to the
glow plug and the intake air is heated. The preheating monitor on
the monitor panel lights up when the switch is turned ON.
Do not turn the switch to the ON position when not using the
APS.
A0207950
2-17
11. EXPLANATION
5.
OF COMPONENTS
LOCKUP MODE SWITCH
This is used when greater power is needed rather than larger

The system is switched between torque converter drive and
direct drive to match the load. When the switch is turned ON, the
torque converter lock-up pilot lamp lights up.
OFF position:
ON position:
2-18
Torque converter drive

Used when greater power is needed, rather than
larger production (such as when dozing loose soil).
The system is switched between torque converter
drive and direct drive to match the load.
OFF
ON
LJ
AD051790
11 .I.6 F: LAMPS (MACHINES
EQUIPPED WITH CAB)
AE210370
1.
WARNING
LAMP
NOTICE
If the alarm buzzer sounds, stop work immediately and carry
out inspection and maintenance of the appropriate point.
When the monitor for the B CAUTION and C CAUTION groups
on the machine monitor system flashes, the warning lamp also
flashes at the same time.
If the lamp flashes, check the monitor panel to locate the
problem.
When the monitor inside the C CAUTION group flashes, the
alarm buzzer also sounds continuously.
2.
TORQUE CONVERTER LOCKUP PILOT LAMP

When the lockup switch of the switch panel is switched ON, this
lamp lights up automatically after the torque converter is locked up
(when it changes to direct drive).
When the torque converter drive is being used, this lamp remains
OFF.
2-19
11. EXPLANATION
OF COMPONENTS
11.1.6 F: LAMPS (MACHINES
EQUIPPED WITH CANOPY)
AE210460
1.
WARNING
LAMP
NOTICE
If the alarm buzzer sounds,
out inspection and maintenance
stop work immediately

and carry
of the appropriate
point.
When the monitor for the B CAUTION and C CAUTION groups

on the machine monitor system flashes, the warning
lamp also
flashes at the same time.
If the lamp flashes, check the monitor
panel to locate the
problem.
When the monitor inside the C CAUTION
group flashes, the
alarm buzzer also sounds continuously.
2.
TORQUE CONVERTER LOCKUP PILOT LAMP
When the lockup switch of the switch panel is switched ON, this
lamp lights up automatically
after the torque converter is locked up
(when it changes to direct drive).
When the torque converter drive is being used, this lamp remains
OFF.
2-20
11. EXPLANATION
OF COMPONENTS
11.1.6 G: MODE SELECTION SWITCH PANEL

(SHOE SLIP CONTROL)
l
l
l
l
Press each mode switch to turn it ON or OFF and to select the

mode.
For details of the setting of the mode to use, see 12.13 Effective
use of mode selection system.
It is impossible to use any combination
of the lock-up mode and
any other mode.
The economy mode, reverse slow mode, and shoe slip control
mode can be used independently
or in combination.
AW22524B
Selecting the mode to match the type of work and quality of rock
or soil makes it possible to carry out operations effectively.
Dozing
Ripping
Reverse slow
mode
Sfcr(o=es[P
Lock up
mode
Ec;od~~
0
X
1.
LOCK UP MODE SWITCH

This is used when large power is needed rather than high
The drive is switched between torque converter drive and direct
drive according to the load. When it is ON, the lamp lights up.
AW22525B
2-20-l
11. EXPLANATION
OF COMPONENTS
ECONOMY MODE SWITCH

This is used for hauling work after ripping or for dozing blasted
rock.
When the system is OFF, if the switch is pressed once, mode [I]
lights up, and if it is pressed again, mode 121 lights up. Select the
mode according to the type of rock.
2.
AW22526B
3.
SHOE SLIP CONTROL SWITCH

This is used for ripping operations.
When it is switched ON, the lamp lights up.
NOTICE
If the shoe slip control is switched
is automatically
set to 131, so switch
match the type of rock.
ON, the rock selection mode

the rock selection mode to
4.
ROCK SELECTION MODE SELECTOR SWITCH

When carrying out ripping work, turn the slip control
select mode [II - 151 according to the shoe slip ratio.
The lamp for the selected mode lights up.
ON and
1
SOFTO
2
0
3
0
4
0
5
OHARD
AW2252BB
5.
REVERSE SLOW MODE SELECTOR SWITCH

Use this after ripping and when dozing rock.
When it is turned ON, the lamp lights up..
06
SLOW
REVERSE
MODE
ON
ON
2-20-2
Il.
EXPLANATION OF COMPONENTS
SWITCHES
AE208070
1.
HORN SWITCH
The horn sounds when the button at the rear of the blade control
lever at the right side of the operators seat is pressed.
I
2.
ROOM LAMP SWITCH (MACHINES

This lights up the room lamp.
ON position: Lamp lights up
OFF position: Lamp is out
AE208080
EQUIPPED WITH CAB)
AD051820
2-21
3.
WIPER SWITCH (MACHINES
EQUIPPED WITH CAB)
This activates the wipers.

The wiper switches are as follows.
@ Left door
@ Front window
@ Right door
@ Rear window
This is also used as the window washer

The switch is operated as follows.
switch.
Window washer only

Keep the switch pressed to the OFF position to spray out water.
I
0
Wiper only
If this is switched
on, the wiper
AD051850
J
will start.
AD051860
Wiper and window washer

If this is kept pressed to the ON position
working, water will be sprayed out.
while
the wiper
is
ADO51870
2-22
REMARK
When installing the cab, check the colors of the washer tank and
window washer hoses, and be sure to connect correctly.
For
right
door(red),
For
front
(color,less)
window
(black)
Red-Right
door
Blue-Left
door
Black Rear window
Colorless-front
window
View
4.
ClGARElTE
LIGHTER (MACHINES
From fuse
box
Red( back
uo
Doewr source)
AEZoBloB
EQUIPPED WITH CAB)
This is used to light cigarettes.

When the cigarette lighter is pushed in, it will return to its
original position after a few seconds, so take it out to light your
cigarette.
Cigarette lighter capacity: 120 W
NOTICE
This cigarette
lighter is 24V. Do not use it as the power source
AD051830
for 12 V equipment.
2-23
11.3
CONTROL
LEVERS AND PEDALS
ADO55346
1.
FUEL CONTROL LEVER
0
0
This lever is used to control the engine speed and output.

Engine stop position: Push the lever forward fully.
Low idling position:
Pull the lever from engine stop position
until you feel the operating force falls
High idling position:
@I
Off.
2-24
Pull the lever fully from

tion.
low idling posi-
AE206120
2.
JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER)

This is used to select the direction of travel, to carry out steering,
and to carry out counterrotation turns.
Forward-reverse shifting
0: FORWARD
0: REVERSE
N: NEUTRAL
Push the lever forward, the machine will move off forward.
Pull the lever backward, the machine will move off in reverse.
Steering
0:
LEFT TURN
8: RIGHT TURN
AE208130
Lever
guide
Move the joystick to the FRONT to travel FORWARD

Move the joystick to the REAR to travel in REVERSE
If the joystick is operated to travel forward or in reverse, and is
then moved partially in the direction of turn, the machine will turn
gradually.
If the joystick is moved further in the direction of turn, the
machine will turn more sharply.
REMARK
If the lever is released when steering the machine, the lever will
return to the @ position or the @ position and the machine will be
returned to straight movement.
If you support the lever guide with your hand when steering, the
turning operation will be easier.
AE20814B
Gear shifting
Rotate the joystick 30 to carry out gear shifting operation.
Position @: 1st
Position @: 2nd
Position 0:
3rd
For details of the maximum speed at each speed range, see 25.
SPECIFICATIONS.
REMARK
When gear shifting
the rear of the joystick
1st: iiJis displayed on
2nd: qis displayed on
3rd: flis displayed on
operation is carried out, the display panel at

will display the speed range.
the display panel
the display panel
the display panel
2-25
3.
BRAKE PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.

Depress
4.
the pedal to apply the right and left brakes.
DECELERATION
I-
AD051970
PEDAL
A
l
l
WARNING,
Do not place your foot on this pedal unnecessarily.

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.
This pedal is used when reducing the engine speed or stopping

the machine.
When switching between forward and reverse, or when stopping
the machine, use this pedal to reduce speed.
5.
PARKING
LEVER
A
When the machine
LOCK position.
WARNING
is parked, always
set the parking lever to the
This lever is used to apply the parking
brake.
REMARK
l
If the parking lever is set to the LOCK position when the directional and steering lever is at the forward or reverse position, the
directional and steering lever is automatically
returned to the N
position.
l
When starting the engine, if the parking lever is not at the LOCK
position, the limit switch is actuated and the engine cannot be
started.
2-26
AD451665
6.
SAFETY LEVER
TROL LEVER)
(FOR BLADE
CONTROL
LEVER,
RIPPER CON-
WARNING
g
When standing up from the operators seat, always set the
safety lever securely to the LOCK position.
If the blade control and ripper control levers are not locked
and are touched by accident, it may lead to serious injury or
damage.
If the safety lever is not set securely to the LOCK position, the
lock may not be applied.
Check that it is in the position shown in the diagram.
When parking the machine or when carrying out maintenance, always lower the blade and ripper to the ground, then
set the safety lever to the LOCK position.
This safety lever is a device to lock the blade control and ripper
control levers.
When it is set to the LOCK position, the TILT, RAISE, LOWER, and
FLOAT operations are locked.
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 starting the engine, to ensure safety, always set the safety
lever to the LOCK position.
2-27
7.
BLADE CONTROL LEVER

(POWER TILTDOZER)
This lever is used to raise or tilt the blade.
Lifting control
@ RAISE : t k,
@ HOLD
3x1
@
Blade is stopped and held in this position.

LOWER : ( * )
FLOAT :(_I%
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.
Lower
AD20816B
Tilting control
@ LEFT TILT : ( 1& 1
@ RIGHT TILT: (&)
Right
tilt
1
_.---
.._
Left
tilt
AD209178
J
7.
BLADE CONTROL LEVER

(FOR DUAL TILT DOZER)
This carries out the blade lift, tilt, dual tilt, and pitch operations.
Liiing control
@ RAISE : (&
@ HOLD
: ( -b
@
@
1
1
Blade is StoDDed and held in this position.

LOWER : ( &
1
FLOAT : (a
1
Blade will move freely according to external
force.
Ra
REMARK
When released from FLOAT position, this lever will not return to
HOLD position, so it must be moved back by hand.
Lower
Tilting control
@
LEFT TILT
RIGHT TILT
A0208168
: (1&
: (&
1
)
Right
tilt
AO20817B
2-28
l
DUAL TILT OPERATION
@ + @: Left dual tilt (keep
+ @:
button 0 pressed and operate in

direction @.)
R$ht tilt (keep button 0 pressed and operate in direction
B.
If the tilt operation is carried out with button @ at the top center
of the knob kept pressed, a larger tilting force can be obtained than
in normal tilt operations.
l
PITCH OPERATION
@ + @: Rear pitch: Smaller
cutting edge angle (keep button @

pressed and operate in direction @.I
@ + @I: Forward pitch: Larger cutting edge angle (keep button @I
pressed and operate in direction @.I
Return the lever to the neutral position, then keep button @ at
the front center of the knob pressed, and operate the tilt to change
the angle of the cutting edging of the blade.
PRECAUTIONS WHEN USING DUAL TILT, PITCH

l
If the tilt operation is carried out with buttons @ and @ both

pressed at the same time, the blade will be pitched. (The pitch
operation is the priority circuit.)
To make effect use of the dual tiltdozer, see OPTIONS, ATTACHMENTS.
REMARK
l
@
@
l
@
@
l
For the dual tilt and pitch operations,

keep the button pressed
and move the lever to the left or right to start the actuation.
The pitch operation is the priority circuit, so if both buttons are
pressed at the same time, the pitch will be operated.
+ @ Left dual tilt (+@I
+ @ Right dual tilt C&*)
The dual tilt operation can be carried out at any of the RAISE,
HOLD, or LOWER positions.
If the dual button is not pressed, the normal tilt operation can be
carried out.
+ @ Rear pitch (&..
+ @ Forward pitch (k)
The pitch operation can be carried out at any of the RAISE,
HOLD, or LOWER positions.
2-29
RIPPER CONTROL LEVER (FOR VARIABLE RIPPER)

This is used to operate the ripper.
RAISE (e
1
HOLD
( 9 1: Ripper is stopped
LOWER( 78 1
Digging
smaller.
Digging
larger.
angle
reduced
angle increased
( 9&
( y2
and held in the same position.
) : Cutting
angle
(CL) becomes
1: Cutting
angle
(4
k--2-21
becomes
AEZOBEIB
OigsinQ
decrease
9.
angle
*
OigginQ
cs
angle
increase
AE208228
PIN PULLER CONTROL SWITCH (FOR GIANT RIPPER)

This is used to operate
@
@
the pin puller.
PULL OUT: Pin is pulled out.

PUSH IN: Pin is pushed in.
43
Front of the machine
AC052080
2-30
11.4
DUST INDICATOR
This device indicates clogging of the air cleaner element.

When the red piston appears in transparent
part @ of this
indicator, the element is clogged. Clean the element immediately.
After cleaning, push indicator button @to return the red piston
to its original position.
The dust indicator is on the air cleaner bracket inside the engine
room.
AK069991
11.5 POWER SOURCE

The cigarette
lighter socket can be use as a power
source.
NOTICE
The power from the cigarette lighter socket is 24V. Do not use
this as the power source for any 12V equipment.
The capacity of the cigarette lighter power source is 120W (24V
x 5AL
11.6
FUSE BOX
NOTICE
Before replacing
a fuse, be sure to turn off the starting switch.
The fuses protect

burning out.
If the fuse becomes
the fuse is loose in the
Replace a fuse with
l
the
electrical
equipment
and wiring
from
corroded, or white powder can be seen, or

fuse holder, replace the fuse.
another of the same capacity.
Chassis
Fuse box I is installed
inside the cover (left).
Cab (machines equipped with cab)

Fuse box II is installed at the bottom
of the overhead
panel.
2-31
11. EXPLANATION
OF COMPONENTS
11.6.1 FUSE CAPACITY
AND CIRCUIT NAME
FUSe
DOX
Fuse box I
No.
Fuse capacity
Circuit
20 A
Starting
20 A
Car stereo,
switch
@I
@I
@I
a I
20 A
@I
@I
a3 I
20 A
Backup
15A
Horn
20 A
Rear lamp
20~ I---~
20 A
Head
IO A
Monitor,
Fuse box II (Machines
-0 I
lamp,
work
pin-puller
equipped
with
1
Radio
20 A
Radio,
10 A
Rear wiper
10 A
Right door wiper
10 A
Front wiper
10 A
2-32
lamp
switch,
air conditioner
cab)
Circuit
10 A
AE20019B
alarm
-0
capacity
lamp
10 A
IFuse
room
Lock up
No.
lighter,
10 A
cigarette
I Left
memory
lamp,
cigarette
door wiper
lighter
Fuse box II
11.7
DOOR-OPEN LOCK
(MACHINES EQUIPPED
WITH CAB)
Use this when your want to keep the door held open.
1. Push the door against door catch 0. The door will be held by the
door catch.
2.
To release the door, move lever @ inside the cab to the front of
the cab. This will release the catch.
NOTICE
When keeping
l
Always close
tions. Leaving
l
Keep the door
The door may
l
the door open, fix it securely to the catch.

the door when traveling or carrying out operathe door open will cause the door to break.
locked open securely.
swing closed because of the vibration.
AD052160
11.8
SASH GLASS INTERMEDIATE

LOCK
(MACHINES EQUIPPED WITH CAB)
When carrying out operations with the cab sash glass open, use
this block to prevent the glass from moving.
l
When the lever is at the FREE position, the glass can be opened
or closed.
l
When the lever is moved to the LOCK (up or down) position, the
glass is fixed in position.
l
If the glass is not held securely, set the lever in the FREE position
and rotate clockwise to strengthen the holding power.
l
To reduce the holding power, turn counterclockwise.
ti
NOTICE
Always close the window when traveling or carrying
tions. Leaving the window
open will cause the window
out operato break.
_
Tighten
11.9
DOOR POCKET
(MACHINES EQUIPPED
Lock 0
WITH CAB)
These are on the inside of the left and right doors, and can be
used for keeping things. However, do not put tools or other heavy
objects in the pocket. If the pocket becomes dirty, turn three clips 0,
remove the pocket and wash it.
11. IO ASHTRAY
(MACHINES
EQUIPPED
WITH CAB)
This is on the left side of the operators seat.

Always
make sure that you extinguish
the cigarette
closing the lid.
before
2-33
ll.ll
TOOL BOX
This is inside the front of the right fender.

It is used for storing tools.
2-34
11 .I2 USING CAR STEREO

(MACHINES EQUIPPED
11.12.1
EXPLANATION
WITH CAB AND CAR STEREO)
OF PARTS
ADO54320
Symbol
Control
function
Name
1 ON/BAL/VOL
Radio power
Control
method
Explanation
PUSH
Each time the button

between
ON/OFF
is pressed,
the radio is switched
ON and OFF. This switch
does not work when
the tape is being used.

Volume
balance
PULL
Pull the knob and turn clockwise

>
from the right speaker;
PULL
the sound
3
return the knob to its original
Turn to adjust the volume.

Low 0
Sleep timer
Automatic
power
High
Radio power
ON
OFF
the volume
This switch
position.
has no effect on
of the alarm.
If the radio power

ACC-OFF,
the sound
to emphasize
from the left speaker.
After adjusting,
Volume
to emphasize
turn counterclockwise
is turned
ON when
the switch
the radio or tape starts and the power
is at
goes OFF
after 1 hour.
Control
of low
Release
push lock
sounds
Control
sounds
From the center:

Turn
CLOCKWISE
Turn
COUNTERCLOCKWISE
to BOOST
to CUT
of high
-
2-35
Symbol
Name
Control
method
Recall Channel
Control
function
1
Explanation
Push the button
Frequency
set in Channel
1 is called
up
for less than 2.0

seconds
Save Channel
(memory)
Push the button
The frequency
for more than 2.0
(saved to memory)
in the display
is set to Channel
seconds
See 1
2, 3. 5
0
@
When
4KlB
using
radio: Channel
When
See 1
See 1 (only channel
See 1
See 1
using tape:
PUSH
Each time button
Dolby ON/OFF
When
5APC
When
it is switched
between
is pressed,
it is switched
between
ON
See 1
See 1
PUSH
Each time
button
and OFF.
When
using tape:
APC ON/OFF
possible
Manual
is pressed,
and OFF.
using
radio: Channel
is different)
down
Push the button
it is ON, APC (finding
ON
beginning)
is
in FWREW.
Frequency
goes down
one step (AM 9 kHz, FM 100 kHz)
for less than 0.5

seconds
Seek down
Push the button
When
for more than
Seeks down
0.5
button
is being
pressed,
from frequency
changes
where
to fast forward.
button
is released.
seconds
Manual
up
Push the button
Frequency
goes up one step (AM 9 kHz, FM 100 kHz)
for less than 0.5

seconds
Seek up
Push the button
1 for more than
1 EJECT
1 EJECT
1PUSH
0.5
When
button
is being
pressed,
1Seeks
up from frequency
1When
using tape (PLAY/FF/REW),
changes
where
to fast forward.
button
is released.
seconds
@
This can also be used when

0
REW
PRO
Rewind
Changes
PUSH
between
A side and B side
Rewinds
tape during
Push the button
Changes
between
during
direction
of the tape.
PLAY
tape
press to eject cassette.
switch
is at ACC-OFF.
PLAY or FF
A side and B side and changes
PLAY from
Push the button
FWREW
during
FF
Fast forward
PUSH
Push this button to fast forward
PS/AS
PS
Push the button
Receives
(Preset Scan)
for less than 0.5
However,
seconds
sensing.
AS
Push the button
When
(Auto Store)
for more than 0.5
band and stores frequencies
seconds
starting
Push this button to play tape during
the
FF/REW
FWREW
preset channels
it skips channels
Display
flashes
AS is turned
tape during
for 5 seconds
which
during
do not yet have stop
PS.
ON, it searches
from Channel
from
in memory
1. When
PLAY/REW
each.
bottom
(preset
of
memory)
doing this, it searches
during the 1st cycle at LO and during the 2nd cycle at DX.
However,
so there
twice.
it skips any frequencies
When
is also carried
2-36
that are already
is no case of the same frequency

the illumination
out at LO.
is lighted
stored,
being stored
up, the 2nd cycle
Symbo
Name
ARM
Control
Control
function
method
Alarm
ON/OFF
PUSH
Explanation
Alarm
when
Alarm/wake-up
PUSH
selection
can be turned
ON/OFF
time or frequency
If button
is pushed
it switches
when
between
by pushing
alarm time is being displayed,
alarm
and wake-up.
being
used, A is displayed
When
the time set for the alarm
is ON, the alarm
sound
This also works

When
when
the wake-up
LCD channel
the same
When
the alarm
on the LCD channel

is reached
is
display.
and the alarm
from the PS on the right side.

switch
is being
display.
button
is being displayed.
is at ACC-OFF.
used, U is displayed
When
on the
the time set for the wake-up
as the actual time and the alarm
is
is ON, the radio
or tape starts to play.

This also works when
Stop alarm
The alarm
sound
stop the alarm,
switch
is at ACC-OFF.
stops after 3 minutes,
push any button
With wake-up,
the radio or tape stops after 1 hour, but if
you wish to stop the tape or radio,
II)),)
(HI WAY)
Highway
traffic
information
ON/OFF
(HW)
USH
push the radio power
button
(when
using the radio) or push the EJECT button
(when
using the tape) to turn the power
This key turns the highway

This system
works
when
but returns to original
traffic
If the key is pressed

setting
model
when
and released
OFF. The frequencies
Method
setting
is 1620 kHz.
2 seconds,
if the key is pressed

is displayed.
the
for more
The.
t I I)))
reception.
of canceling
1. Push HW
2. Turn
within
the other frequency
mark lights up during
ON/OFF.
using tape or radio (AM/FM),
is displayed;
than 2 seconds,
OFF.
information
are 1620 kHz and 1629 kHz; the default
present
but if you wish to
or turn the tape to IN.
( 1I I))) ).
radio OFF.
3. Insert cassette.
4. If HW is selected
PRO/FF/REW/EJECT
when
playing
buttons
tape,
to cancel
push any of
HW.
2-37
Symbol
Name
DISP
Control
Control
function
method
Display
selection
PUSH
Explanation
Each time
it is turned
ON, display
changes
as follows.
Frequency
IWhen using radio)
\
I(
Alarm time
-j
Present time
If the key is released,

seconds,
the frequency
then the alarm
time
If no other key is operated,

the present
is displayed
is displayed
the display
for 5
for 15 seconds.
then
returns
to
time.
To distinguish
between
time, the alarm
the present
mark f&j) flashes
time and the alarm
when
the alarm time is
being displayed.
This key cannot
Resetting
Setting
time
time,
alarm
present
be
used
WAkeys
(Alarm/present)
Keep the DISP key pressed
hour and theAkey
Resetting
minute
and second
DISP key and ARM
display,
time
display
ON/OFF
PUSH
Changing
reception
band
time
the display
Each time the button
is less than 30 min., the
will advance
is pushed,
When
it is ON, LD is displayed
When
it is ON, the soft sounds
Push the button
AM 1 switches
to FM 1
for less than 2.0
FM 1 switches
to AM 1
seconds
AM 2 switches
to AM
FM 2 switches
to FM 1
Push the button
AM 1 switches
to AM 2
FM 1 switches
to FM 2
seconds
AM 2 switches
to AM
FM 2 switches
to FM 1
Only the memory
1 and 2 are switched
on the LCD.
are boosted.
for AM
is
it will switch the loudness
for more than 2.0
time.
time
to the next hour.
ON and OFF.
FM 2 differs; the reception
2-38
and turn ARM ON.
will return to 00 set; with the minute
if the displayed
between
BAND
key to set the
will return to 00 min., and if the displayed
30 min. or more,
Loudness
and use the v
to set the minute.
Keep the DISP key pressed

The second
for
display
LOUD
auto tuning.
Use the DISP key to display the item to be set.
time
present
during
Use DISP key and
1 and AM 2 and for FM 1 and

frequency
is the same.
for both AM and FM at the same
11 .12.2
PRECAUTIONS
WHEN USING
If the head is dirty, clean it with a head cleaning
Never touch the head with a magnet,

hard object.
Use a pencil to wind the tape to the outside to remove any slack.
When
Put the tape in its case. Do not keep the tape in any of the
following places.
On top of the instrument panel
Any place where it is exposed to direct sunlight
Any place that is excessively humid
Any place that is excessively dusty
Any place where there is a strong magnetic field (near a speaker,
etc.)
Any place where there is high temperature
(near the car heater,
etc.)
0
0
0
0
0
0
not listening
to the cassette
screwdriver,
tape, always
tape.
or any other
remove
it.
Use a C-60 (60 minute) tape. Avoid using longer tapes as far as
possible. In particular, do not use C-120 (120 minute) tapes.
These tapes easily get caught up in the machine.
When
Do not put anything

port.
When cleaning, wipe off the dirt with a dry cloth. Never use any
organic solvent such as thinner of benzene.
replacing
the fuse, always
use a 5A fuse.
except a cassette tape in the tape insertion
2-39
11.13 HANDLING AIR CONDITIONER

11.13.1
COOLING OPERATION
When the cooling

is cooled.
operation
is carried out, the inside of the cab
Cooling (RECIRC)
When the control switch and lever are operated as shown in the
diagram, a cool breeze is sent out.
Use this position when strong cooling is needed.
l
Press switch 0.
e
Place levers @ and @ in the position shown in the diagram.
l
Set switch @ to the desired position.
AD051626
Cooling (FRESH)
If the air inside the cab is no longer fresh, set FRESH/RECIRC
selector lever @ to FRESH to bring in fresh air. Keep the other
switches at the same positions as for cooling (RECIRC).
In this position, the inside of the cab is pressurized to prevent
the entry of dust.
REMARK
l
e
l
If the cooling effect is reduced, set FRESH/RECIRC selector lever

@ to RECIRC again. This increases the cooling effect.
New Freon R134a is used as the refrigerant.
The tightening torque for the air conditioner gas piping thread
is as follows.
Thread
Discharge
size
22 x 1.5
Liquid 16 x 1.5
Suction
2-40
24 x 1.5
Tightening
torque
Nm (kgm)
19.6 - 24.5 (2 - 2.5)

11.8 - 14.7 (1.2 - 1.5)
29.4 - 24.3 (3 - 3.5)
11.13.2
HEATING OPERATION
When the heating

is heated.
operation
is carried out, the inside of the cab
AD051628
Heating (RECIRCI
When the control switch and lever are operated as shown in the
diagram, warm air is sent out. Use this position when strong cooling
is needed.
l
Place levers @ and @ in the position shown in the diagram.
l
Set switch @ to the desired position.
AD051629
Heating (FRESH)
If the air inside the cab is no longer fresh, set FRESH/RECIRC
selector lever @ to FRESH to bring in fresh air. Keep the other
switches at the same positions as for heating (RECIRC). In this
position, the inside of the cab is pressurized to prevent the entry of
dust.
AD05162A
REMARK
If the cab is not heated up sufficiently,
turn FRESH/RECIRC
selector lever @ back to RECIRC. This increases the heating effect.
Dehumidifying
and heating
Push switch 0. When temperature
control lever @ is placed at
the central position, dry warm air blows out.
Keep the other switches at the same positions as for heating
(FRESH).
REMARK
If this is used in spring and fall on rainy days when the air inside
the cab is damp, there is no problem of the windows misting up, and
the cab be warmed up to a comfortable
temperature.
2-41
11.13.3
PRECAUTIONS WHEN USING AIR

CONDITIONER
Carry out ventilation

from time to time when using the cooler.
l
If you smoke when the cooler is on, the smoke may start to hurt
your eyes, so turn the lever to FRESH to remove the smoke while
continuing the cooling.
l
When running the air conditioner for a long time, turn the lever
to the FRESH position once an hour to carry out ventilation and
cooling.
Be careful not to make the temperature
in the cab too low.
When the cooler is on, set the temperature
so that it feels slightly
cool when entering the cab (5 - 6C lower than the outside
temperature).
This temperature
difference is considered to the
most suitable for your health, so always be careful to adjust the
temperature
properly.
Direction of vents when cooling

l
If the vents (left and right) in the middle of the dashboard are
turned so that cold air plays directly on the cab door glass,
moisture may condense on the outside of the cab door glass and
reduce the visibility. (This occurs particularly in high temperatures.)
If this happens, turn the vent fully to the rear and raise the air
conditioner temperature
setting slightly.
11.13.4
INSPECTION DURING OFF-SEASON
Even during the off-season, run the compressor at low speed for
several minutes once a week to prevent the loss of the oil film at the
lubricated parts of the compressor. (Run the engine at low speed and
set the temperature
control lever at the central position.)
REMARK
When the ambient temperature
is low, if the compressor
is
suddenly run at high speed, it may cause failure of the compressor.
Note that the system is set so that the compressor will not run
when the cooler switch is turned on if the ambient temperature
is
less than 2 - 6.5C.
2-42
11.13.5
PROCEDURE FOR REPLACING
RECEIVER
Replace the receiver once every two years.

After replacing the receiver, add compressor
oil. Turn the receiver at an angle and measure the oil remaining inside the receiver,
then add the same amount of oil (Denso Oil 6) to fill the receiver.
REMARK
Depending
be shorter.
on the condition
of use, the replacement
interval may
REMARK
If the receiver is used when the desiccant has exceeded the water
absorption
limit, the refrigerant circuit may become clogged and
cause failure of the compressor.
Precautions when replacing receiver
If the receiver is left for more than 15 minutes with the blind
cover removed, the moisture in the air will be absorbed, and this
will reduce the life of the desiccant. If you remove the blind
cover, connect the piping quickly, evacuate the system and fill
with refrigerant.
l
When removing the refrigerant from the refrigerant circuit, release it gradually from the low pressure side to prevent oil from
flowing out.
11.13.6
CLEANING
AIR FILTER
If the air filter for the FRESH or RECIRC air intake becomes
clogged, the cooling or heating capacity will drop. To prevent this,
clean the air filter with compressed
air once a week.
For details of the cleaning method, see 24.2 WHEN REQUIRED.
11.13.7
CHECK COMPRESSOR BELT TENSION

REFRIGERANT (GAS) LEVEL
If the compressor
belt is loose, or the refrigerant
cooling is not carried out efficiently.
For details, see 24.2 WHEN REQUIRED.
AND
level is low,
2-43
11 .I4 HANDLING HEATER

(MACHINES EQUIPPED
11.14.1
METHOD
WITH CAB)
OF OPERATION
To heat quickly
Set the switches to the position shown in the diagram
right to carry out heating quickly.
l
Set FRESH/RECK
selector lever 0 and temperature
lever @ to the position in the diagram on the right.
l
Set blower switch @ to position 3 (HIGH).
on the
control
NOTICE
If heating is carried out continuously for a long period with the
lever at the RECIRC position, the air inside the cab will become
stale, so when the cab is warmed up, always set the FRESH/RECIRC
selector lever @ to the FRESH position.
In this position, the inside of the cab is pressurized to prevent
the entry of dust.
Normal use
Set each switch to the desired
11.14.2
CLEANING
position.
AIR FILTER
If the air filter for the FRESH or RECIRC air intake becomes
clogged, the heating capacity will drop. To prevent this, clean the air
filter with compressed
air once a week.
For details of the cleaning method, see 24.2 WHEN REQUIRED.
2-44
11.15 HANDLING
ACCUMULATOR
for a short time

after the engine is stopped, if the work equipment control lever
is moved to the LOWER position, the work equipment will move
down under its own weight.
After stopping the engine, always place the safety lever in the
LOCK position.
The accumulator
is filled with high-pressure
nitrogen gas, and
it is extremely
dangerous
if it is handled in the wrong way.
Always observe the following
precautions.
l Never make any hole in the accumulator
or expose it to flame
or fire.
l Do not weld any boss to the accumulator.
l When disposing of the accumulator,
it is necessary to release
the gas from the accumulator, so please contact your Komatsu
distributor.
I
The accumulator
is a device to store the pressure in the control
circuit, and when it is installed, the control circuit can be operated
for a short time even after the engine is stopped. Therefore, if the
control lever is moved in the direction to lower the work equipment,
it is possible for the work equipment to move under its own weight.
The accumulator
is installed to the position shown in the diagram on the right.
11.15.1
METHOD OF RELEASING PRESSURE IN

OPERATING CIRCUIT ON MACHINE EQUIPPED
WITH ACCUMULATOR
1.
Lower the work equipment
and stop the engine.
2.
After stopping the engine, operate the control lever fully to the
front, rear, left, and right to release the pressure inside the work
equipment
circuit.
However, the pressure cannot be completely removed, so when
removing the work equipment circuit, loosen the screw slowly,
and never stand in the direction where the oil spurts out.
2-45
12. OPERATION
12.1
CHECK BEFORE STARTING
12.1.1 WALK-AROUND
ENGINE
CHECK
Ah WARNING
Leakage of oil or fuel, or accumulation

of flammable
material
around high temperature
parts, such as the engine muffler or
turbocharger,
may cause fire.
Check carefully, and if any abnormality
is found, repair it or
contact your Komatsu distributor.
Do not get on or off the machine from the rear. Using this
position is dangerous
because it is easy to slip and you
cannot be seen from the operators
compartment.
Always
use the handrail and step at the side when getting on or off
the machine.
When
horizontal
inspecting, if the machine is at an angle,

place to carry out the check.
move
it to a
Before starting the engine, look around the machine and under
the machine to check for loose nut or bolts, or leakage of oil, fuel,
or coolant, and check the condition of the work equipment
and
hydraulic system. Check also for loose wiring, play, and collection
of dust at places which reach high temperatures.
Always carry out the items
engine each day.
in this section
before
starting
This handrail
getting
on or
the
must not be useu

off
the machine
6----k
This handrail
getting
on or
7
2-46
for
1
5
must not be used

off
the machine
for
AE208326
12. OPERATION
1.
Check for damage, wear, play in work equipment,

cylinders,
linkage, hoses
Check that 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 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 water or oil around engine

Check that there is no leakage of oil from the engine or leakage
of water from the cooling system. If any abnormality
is found,
repair it.
4.
Check for oil leakage of oil from power train case, final drive
case, hydraulic tank, hose, joints
Check that there is no oil leakage. If any abnormality
is found,
repair the place where the oil is leaking.
Check for leakage of oil from the undercover. Check the ground
for traces of oil leakage.
5.
Check the undercarriage

(track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from rollers
If any damage, wear, or oil leakage is found, repair the problem
and tighten the bolts.
6.
Check for damage to handrail, loose bolts

Repair any damage and tighten any loose.
7.
Check for damage to gauges, lamps on instrument panel, loose

bolts
Check that there is no damage to the panel, gauges and lamps.
If any abnormality
is found, replace the parts. Clean off any dirt
on the surface.
8.
Check for damage to seat belt and mounting clamps

Check that there is no abnormality
in the seat belt or mounting
clamps. If there is any damage, replace with new parts.
2-47
12. OPERATION
12.1.2 CHECK BEFORE STARTING

Always carry out the items
engine each day.
in this section
before
starting
Machines
the
eauiooed
with
Cab
CHECK MACHINE MONITOR

1. Turn starting switch @ to the ON position.
2.
Check that all monitor lamps and gauges light up for 3 seconds
and the alarm buzzer sounds for about 2 seconds.
AE208338
Machtnes
REMARK
If the lamps do not light up, there may be a failure or disconnection
in the monitor, so please contact your Komatsu distributor.
eauitmed
with
CanODY
NOTICE
When carrying out the checks before starting, do not relay only
on the monitor.
Always
carry out all the items listed for the
following
check and maintenance.
OFF
CHECK COOLANT
LEVEL, ADD WATER
I-
WARNING
START
AD052290
-I
Do not remove cap 0, @ while cooling water is hot. Hot water

may spout out.
When removing cap @I, @ wait until the water temperature
goes down and release radiator
pressure little by little by
loosening caps slowly, then remove the cap.
1. Remove radiator cap 0 and check that coolant is above the
bottom of the strainer as shown in the diagram. If necessary, add
water through filler of radiator cap 0.
2.
Check that there
is no abnormality,
such as oil in the coolant.
3.
If the water level is low, add water through fillers of both radiator
cap @ and subtank cap 0. Add into the subtank up to the level
above the bottom of strainer through filler of cap @ as shown
in the diagram.
4.
To refill the radiator, first stop the engine and pour in water until
the water overflows the filler opening. Then, start the engine,
check the water level again after a five-minute
idling, and add
water if necessary.
5.
After adding
6.
If the volume of coolant

possible water leakage.
2-48
water,
tighten
the cap 0,
added
Radiator
7ta?
AE20092B
Subtank
@ securely.
is more than
usual, check for
AE200938
12. OPERATION
CHECK FUEL LEVEL, ADD FUEL
-A
When adding
a fire.
1.
2.
AND
3.
WARNING
fuel, never let the fuel overflow.
This may cause
Turn the engine starting switch to the ON position and check the
fuel level with fuel level gauge @ on the monitor panel.
After checking, turn the switch back to the OFF position.
428
After completing work, fill the fuel tank through fuel filler port 0.
Check the fuel level with the fuel gauge at the fuel filler port.
For details of the fuel to use, see 20. USE OF FUEL, COOLANT
LUBRICANTS
ACCORDING
TO AMBIENT TEMPERATURE.
After adding fuel, tighten the cap securely.
Fuel capacity: 1050 1 (277 US gal, 231 UK gal)
REMARK
l
When dozing on a grade, make sure there is plenty of fuel in the
tank so that the engine fuel line does not becomes aerated.
l
If breather hole @I on the cap is clogged, the pressure in the tank
will drop and fuel will not flow.
Clean the hole from time to time.
AD054210
2-49
12. OPERATION
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

1. Open the engine side cover on the right side of the chassis.
2.
Remove
dipstick @ and wipe the oil off with a cloth.
3.
Insert dipstick @ fully in the oil filler pipe, then take it out again.
4.
The oil level should
be between
the H and L marks on dipstick
0.
If the oil level is below the L mark, add engine oil through
oil filler
0.
For details of the oil to use, see 20. USE OF FUEL, COOLANT
AND LUBRICANTS
ACCORDING
AL116000
5.
If the oil is above the H mark, remove drain plug 0, loosen drain
valve @ to drain the excess oil, then check the oil level again.
6.
If the oil level is correct, tighten

close the engine side cover.
the oil filler cap securely
and
AL116450
REMARK
l
Check the oil level with the engine stopped.
l
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.
l
If the machine is at an angle, make it horizontal before checking.
l
When adding oil, remove the dipstick from the holder to release
the air inside the crankcase.
2-50
12. OPERATION
CHECK OIL LEVEL IN POWER TRAIN CASE (INCL. TRANSMISSION,

TORQUE CONVERTER AND BEVEL GEAR CASES), ADD OIL
Start the engine and run at idling for 5 minutes, then check the
oil level with the COLD side of dipstick 0.
Remove
dipstick 0,
and wipe the oil off with a cloth.
Insert dipstick @ fully in the oil filler pipe, then take it out again.
be between
0.
oil filler
0.
AND
LUBRICANTS
ACCORDING
5.
If the oil is above the H mark, pull out hose 0, and loosen drain
plug @ to drain the excess oil, then check the oil level again.
6.
If the oil level is correct,
tighten
the oil filler cap securely.
REMARKS
l
l
When the engine is stopped, the oil level will rise, so it is
impossible to check the oil level correctly. When checking while
the engine is running, run the engine at idling and check with the
HOT side of dipstick 0.
l
When working on a slop of more than 20, check that the oil is
up to the H level.
---_w---
AE20WOE
2-51
12. OPERATION
CHECK DAMPER CASE OIL LEVEL, ADD OIL

1. Remove dipstick 0, and wipe the oil off with a cloth.
2.
Insert dipstick
again.
@ fully into the dipstick
3.
be between
holder,
4.
,I
I II 11111/I
\-
then pull it out
0.
If the oil is below the L mark, add engine oil through
holder.
AND
n
the dipstick
LUBRICANTS
ACCORDING
If the oil is above the H mark, drain the excess oil from
plug. After draining the oil, check the oil level again.
drain
REMARKS
l
l
When checking the oil level, if the machine is at an angle, move
it to a horizontal position before carrying out the check.
CHECK BRAKE PEDAL TRAVEL

1. Depress the brake pedal all the way until it stops.
2.
The distance of travel at the center of the pedal (position in the

diagram on the right) should be 65 - 85 mm (2.56 - 3.35 in).
3.
When this value exceeds the specified range, or the brake fails
to work, please contact your Komatsu distributor for adjustment.
2-52
65-65m
AW53630
CHECK OIL LEVEL IN HYDRAULIC
TANK,
ADD OIL
WARNING
When removing the oil filler cap, oil may spurt out, so stop the
engine and wait for the oil temperature
to go down, then turn
the cap slowly to release the internal pressure before removing
the cap.
NOTICE
Do not add oil if the level is above the H line. This will damage
the hydraulic equipment
and cause the oil to spurt out.
1.
Lower the blade to the ground,

about 5 minutes before checking
H and L in sight gauge 0.
stop the engine and wait for

oil level. If oil level is between
Proper range
L
If the level is below the L mark, add engine oil through
2.
oil filler
AD053410
0.
AND
LUBRICANTS
ACCORDING
REMARK
When
horizontal
inspecting, if the machine is at an angle,

move
it to a
WARNING
If oil has been added to above the H mark, stop the engine and
wait for the hydraulic oil to cool down. Then remove drain plug
8, loosen drain valve 0, and drain the excess oil.
2-53
12. OPERATION
CHECK DUST
1. Open the
check that
portion of
INDICATOR
engine side cover on the right side of the chassis,
the red piston has not appeared in the transparent
dust indicator 0.
2.
If the red piston has appeared, clean or replace the element

immediately.
For details of the method of cleaning the element, see 24.2
WHEN REQUIRED.
3.
After checking, cleaning, and replacing, press the knob of dust

indicator @ to return the red piston to its original position.
AD052091
CHECK ELECTRIC WIRINGS
in the electric wiring, always locate and repair the cause.

Check for damage of the fuse and any sign of disconnection or
short circuit in the electric wiring. Check also for loose terminals and
tighten any loose parts. Check the following points carefully.
e Battery
0 Starting motor
l
Alternator
Please contact your Komatsu distributor for investigation and
correction of the cause.
etc.) around the battery may cause fire, so always check and
When carrying walk-around checks or checks before starting,

always check if there is any accumulation of flammable material
around the battery, and remove such flammable material.
2-54
CHECK THAT LAMPS LIGHT UP

1. Turn the key of starting switch to the ON position.
OFF
-START
AD052290
2.
Turn the front lamp and working lamp switch to the ON position
and check that the front lamps and working lamp light up.
AD051790
I
3.
Turn the rear lamp switch to the ON position and check that the
rear lamps on the left and right fenders light up.
OFF
If the lamps do not light up, there is probably a broken bulb or

disconnection
in the wiring, so contact your Komatsu distributor for
repairs.
ON
lJ
AD051790
CHECK HORN SOUND

1. Turn the key of starting
switch to the ON position.
OFF
-START
AD052290
2.
Press the horn switch
and check that the horn sounds.
2-55
12. OPERATION
CHECK BACKUP ALARM SOUND

OFF
START
AD052290
2.
Set the joystick to the REVERSE position. The buzzer must sound
immediately.
The buzzer will continue to sound until the joystick
is moved to the NEUTRAL or FORWARD position.
CHECK SEAT BELT FOR WEAR OR DAMAGE

Check the belt and mounting clamps, and if they are worn
damaged,
replace the seat belt.
2-56
or
12. OPERATION
12.1.3 ADJUST
OPERATORS
A
l
SEAT
WARNING
Adjust the seat position at the beginning

of each shift or
when operators change.
Adjust the seat so that the brake pedal can be depressed all
the way with the operators back against the backrest.
Fore-aft
Pull up
release
Fore-aft
adjustment
of seat
handle 0, set the seat to the desired position,
the handle.
adjustment:
160 mm (6.3 in) (12 stages)
Weight adjustment
of seat
Turn knob @ so that the indicator of the weight
inside knob @ shows your own weight.
Turn the knob to adjust the weight as follows.
To make LIGHTER, turn COUNTERCLOCKWISE
To make HEAVIER, turn CLOCKWISE
The weight
- 117.8 lb)
@
Adjusting
can be adjusted
reclining
within
then
display
(kg)
a range of 50 - 120 kg (110.3
angle
NOTICE
When reclining the seat back to the
behind, and adjust to a suitable position.
Pull lever 0, set the seatback
operate, then release the lever.
ADO53670
rear,
to a position
check
where
the
space
it is easy to
2-57
@
1.
SEAT ANGLE
When lever @ is pulled up,
the seat front. (5 stages)
1. To raise the seat front,
your weight to the seat
2. To lower the seat front,
your weight to the seat
it is possible
to adjust the angle of
keep the lever pulled up and apply

backrest.
keep the lever pulled up and apply
front.
2.
When lever @ is pulled up, it is possible to adjust the angle of

the seat back. (5 stages)
1. To raise the seat back, keep the lever pulled up and stand up
slightly.
2. To lower the seat back, keep the lever pulled up and apply
your weight to the seat back.
ADJUSTING
VERTICAL HEIGHT OF SEAT
Pull up levers @ and @ in turn and adjust the angle.
adjusting, release the levers and lock them.
(Vertical adjustment
amount: 5 stages, 60 mm (2.4 in))
2-58
After
SEAT ADJUSTING
DIRECTION
Move lever @ back to release the lock, then turn the seat to the
right by hand. It is possible to change the direction of the seat
to the 15 position.
After changing the angle of the seat, return the lever securely
and lock it in position.
Adjusting the seat angle to the right is done to make it easier to
carry out ripper operations or scraper towing operations.
12.1.4 OPERATIONS
ENGINE
AND CHECKS BEFORE STARTING
WARNING
If the work equipment

control levers are touched by accident,
the work equipment
may move suddenly. When leaving the
operators compartment,
always set the safety lever securely to
the LOCK position.
I
1.
Check that parking lever @ is

LOCK position, the engine will
If parking lever @ is placed at
returned to neutral even if it
position.
2.
Check that joystick
3.
Check that the blade is lowered to the ground and that blade
control lever @ is at the HOLD position. If it is at the FLOAT
position, the engine will not start.
Machines
wuiD
Machines
eauimed
with
CanODY
locked. If this lever is not at the

not start.
the LOCK position, joystick @ is
is at the FORWARD
(REVERSE)
ACM51665
@ is at the 1st position.
2-59
12. OPERATION
5.
Check that the ripper is lowered
6.
Check that safety lever @ is locked.

If safety lever @ is locked, the blade control lever is returned
the HOLD position even if it is at the FLOAT position.
2-60
to the ground.
to
12.2 STARTING ENGINE
Machines
eouimed
with
cab
Machines
eauitmed
with
CanODY
12.2.1 NORMAL STARTING

4h WARNING
Check that there are no persons or obstacles in the surrounding
area, then sound the horn and start the engine.
NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine will not start, wait for at least 2 minutes before
trying to start the engine again.
1.
Pull fuel control

position.
lever @ a little toward
you from the low idling
AE208508
2.
Turn the key of starting
switch @ to the START
position.
OFF
START
AD052391
3.
When engine is started, release the key of starting switch @ and

the key will return automatically
to ON.
OFF
I
START
ADO52291
2-61
12. OPERATION
12.2.2
STARTING
IN COLD WEATHER
(Starting
with APS (Automatic
Priming
When
starting
in low temperatures,
a
System))
do as follows.
WARNING
Never use starting aid fluids as they may cause explosions.
NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine fails to start, repeat steps 3 and 4 after waiting for
about 2 minutes.
Machines
eauioped
with
Cab
B51B
Machines
eauiDDed
with
CanODY
1. Open fuel valve @ for the APS.
2.
Turn the key of starting switch @to

the engine for IO seconds.
the START position
and run
OFF
START
AD052391
3.
switch @ to the OFF position.
OFF
START
AE20853B
4.
Pull fuel control

position.
lever @ a little toward
you from the low idling
AE20854B
2-62
12. OPERATION
5.
switch
@ to the ON position.
OFF
START
AD052290
6.
When preheating switch @ is turned

@ will also light up, and preheating
ON, preheating pilot lamp

will automatically
start.
AD051790
7.
Keep in this condition until preheating pilot lamp @ goes out.

(Preheating is completed after approx. 12 seconds, and the lamp
goes out.)
0 _
Ins
A0207950
8.
When preheating pilot lamp @ goes off, turn the starting switch
key to the START position and start the engine.
OFF
START
9.
When engine is started, release the key of starting switch @ and

the key will return automatically
to ON.
OFF
I
START
ADO52291
10. When the engine

becomes normal,
runs smoothly
put preheating
and the color of exhaust gas

switch @ in the OFF position.
2-63
12. OPERATION
REMARK
l
The time which should elapse before turning the preheating

switch off varies with the ambient temperature.
Confirm the time
to the table below.
Ambient
Time from the starting of engine

until turning off the preheater switch
temperature
1 - 2 minutes
15 - 0C
Below 0C
3 - 5 minutes
REMARK
l
l
When the air temperature

is below 15X, leave the valve open.
If Step 6 to 8 are carried out without performing Step 1, it may
shorten the nozzle life. Be sure to carry out Step 1.
If the engine does not start through the steps specified above,
return the fuel control lever to the engine stop position and
repeat Steps 2 to 8 at an interval of approx. 2 minutes.
If the switch is moved to START while the preheating pilot lamp
is on in Step 8, glow plugs will get wet, making firing impossible.
This will make it difficult to start the engine.
12.2.3 SPECIAL STARTING

FUEL)
(AFTER RUNNING
OUT OF
When starting the engine after it has run out of fuel, first add fuel,
then bleed the air from the fuel system before starting.
For details on how to bleed the air, see 24.5 500 HOURS
SERVICE.
2-64
12. OPERATION
12.3
OPERATIONS AND CHECKS AFTER

STARTING ENGINE
After starting the engine, do not immediately

start operations.
First, carry out the following operations and checks.
NOTICE
Avoid abrupt acceleration
until warm-up
run is completed.
l
Do not run the engine at low idling or high idling for more than
20 minutes. If it is necessary to run the engine at idling, apply
a load or run at a medium speed from time to time.
l
If engine oil pressure monitor @ flashes or the buzzer sounds
intermittently,
stop the engine and check for the cause.
l
AD208578
12.3.1
NORMAL
OPERATION
1. Pull fuel control lever @ to the center position between LOW
IDLING and HIGH IDLING and run the engine at medium speed
for about 5 minutes with no load (warm-up
run).
2.
3.
After warm-up
run is completed,
check gauges and caution
lamps for proper operation. If any abnormality
is found, repair
it.
Continue to run the engine at light load until engine water
temperature
gauge indicator @ falls within the green range.
Check that there is no abnormal
exhaust gas color,
vibration. If any abnormality
noise,
AE20854B
or
2-65
12. OPERATION
12.3.2 IN COLD AREAS

Pull fuel control lever @ to the center position between LOW
IDLING and HIGH IDLING and run the engine at medium speed
for about 10 minutes with no load (warm-up
run).
AE208546
Operate blade control lever @ to the RAISE position, then keep

the blade raised to the maximum
height and continue to relieve
the circuit for IO minutes.
Finally, operate blade control lever @ and ripper control lever @
to operate all the blade and ripper cylinders several times.
If the oil temperature
in the work equipment
is not properly
raised, there will be a time lag in the response of the work
equipment
and steering.
After warm-up
run is completed,
check gauges and caution
lamps for proper operation. If any abnormality
is found, repair
it.
Continue to run the engine at light load until engine water
temperature
gauge indicator @ falls within the green range.
REMARK
If the oil temperature
in the power train is not raised properly,
it will take longer to accelerate to the maximum
speed.
5.
2-66
Check that there is no abnormal

exhaust gas color,
vibration. If any abnormality
noise,
or
Right tilt
72.4 MOVING MACHINE

a
WARNING
When moving
machine,
check that the area around the
machine is safe, and sound the horn before moving.
Clear all personnel from the machine and the area.
Clear all obstacles from the path of the machine.
Use extreme care when reversing the machine. Note there is
an blind spot behind the machine.
When starting on slopes, always keep brake pedal @ depressed even after releasing parking lever 0.
When starting to travel up a steep hill, pull fuel control lever
0 fully to run the engine at full throttle, and keep brake pedal
@ depressed. Use joystick @ to select Ist, then move it in the
direction of travel and slowly release brake pedal @ to allow
the machine to move off gradually. When the machine has
started moving, release the brake pedal completely.
Machines
1.
Set parking
eauimed
with
CanODv
lever @ to the FREE position.
A0051668
2.
Set joystick
@ to the desired
position.
3.
Set safety lever @ for blade control

lever @ and ripper control
2-67
12. OPERATION
4.
Operate blade control lever @ and ripper control lever @ to the

RAISE position, raise the blade 40 - 50 cm (15.8 - 19.7 in) from
the ground, and raise the ripper to the maximum
height.
5.
Pull fuel control lever 0, raise the

depress decelerator pedal @.
6.
Move joystick @ to the F (FORWARD) or R (REVERSE) position,

gradually release decelerator pedal @ and allow the machine to
move off.
2-68
engine
speed,
and fully
Hold
Raise
12.5
SHIFTING
GEAR
It is possible to change the speed range when traveling,

is no need to stop the machine
1.
Move joystick
when
to the desired
shifting
Machines
eouiooed
with
cab
Machines
esuiooed
with
canooy
so there
gear.
gear position
to shift gears.
Gear shifting
Rotate the joystick 30 to carry out gear shifting operation.
Position @: 1st
Position @: 2nd
Position 0:
3rd
For details of the maximum speed at each speed range, see 25.
SPECIFICATIONS.
REMARK
When gear shifting
the rear of the joystick
1st: qis displayed on
2nd: [z3is displayed on
3rd: His displayed on
operation is
will display
the display
the display
the display
carried out, the display panel at

the speed range.
panel
panel
panel
2-69
12. OPERATION
12.6
;;;F;Ni
BETWEEN
FORWARD
When switching between FORWARD

that the direction of travel is safe.
IA
AND
and REVERSE,
check first
WARNNG
CAUTION
Machines
eouimed
with
Canopy
There is no need to stop the machine even when switching

between FORWARD and REVERSE.
To increase safety, operator comfort, and the life of the transmission, leave the engine running at full speed, and always
depress the decelerator
pedal to lower the engine speed.
1.
Depress
decelerator
pedal @ and reduce the engine
speed.
I
2.
Return joystick @to the neutral position, reduce the speed, then
depress brake pedal @ and stop the machine.
3.
After depressing
desired position.
4.
Release
decelerator
decelerator
pedal 0,
move joystick
pedal @ to raise the engine
REMARK
When the gear shift lever is placed
warning buzzer will sound.
in REVERSE,
AD052400
J-P
Forward
@ to the
speed.
the REVERSE
AD052401
2-70
12.7
STEERING
MACHINE
turning
Avoid
as much as possible
the machine
Never
make a pivot turn at high speed.
while
traveling,
incline
eouiooed
Machines
eauiDDed
with
Catl
on a slope.
12.7.1 NORMAL TURNING

To turn the machine
direction to turn.
Machines
joystick
with
CanODY
@ in the
Turning gradually to left while traveling forward

If the joystick is pushed forward and moved partially to the left
(L), the steering clutch is disengaged
and the machine turns
gradually to the left.
REMARK
When turning gradually to the right, push the joystick forward,
and move it partially to the right.
Do the same when traveling in reverse.
u
l
Making sharp turns to left while traveling forward

If the joystick is pushed forward and moved fully to the left (L),
the steering clutch is disengaged, the brake is applied, and the
machine turns sharply to the left.
AE2086ao
REMARK
When making sharp turns to the right, push the joystick forward,
and move it fully to the right.
AE208690
2-71
12. OPERATION
12.7.2 TURNING WHILE DESCENDING A SLOPE

On steep downhill slopes where the machine may travel under
its own weight, or on downhill slopes where it is being pushed by
a towed machine, the machine will steer in the opposite direction,
so do as follows.
Turning gradually to left while traveling forward

If the joystick is pushed forward and moved partially to the right
(RI, the machine turns gradually to the left. (Becomes reverse
steering)
REMARK
When turning gradually to the right, push the joystick forward,
and move it partially to the left. (Becomes reverse steering)
Making sharp turns to left while traveling forward

If the joystick is pushed forward and moved fully to the left (L),
the machine turns sharply to the left. (Does not become reverse
steering)
REMARK
When making sharp turns to the right, push the joystick forward,
and move it fully to the right. (Does not become reverse steering)
AE208710
2-72
12.8
STOPPING
MACHINE
Machines
eQuitmed
with
cab
WARNING
Avoid stopping suddenly. Give yourself ample room when

stopping.
When stopping the machine, select flat hard ground and
avoid dangerous places. If it is unavoidably necessary to park
the machine on a slope, place the parking lever in the LOCK
position and insert blocks underneath the track shoes. As an
additional safety measure, thrust the blade into the ground.
control lever is touched by accident,
the work equipment
may move suddenly, and this may lead
Before leaving the operators
seat,
always operate the safety lever to place it securely at the
LOCK position.
1.
Depress
brake pedal @I to stop the machine.
NOTICE
If the brake is depressed when the engine speed or travel speed
is high, the brake disc may make a slipping sound. Normally,
depress decelerator pedal @ to reduce the engine speed and travel
speed before depressing the brake.
AD053830
2.
Place joystick @ at the neutral

to 1st.
position
and set the speed range
ME08750
2-73
12. OPERATION
12.9
PRECAUTIONS
12.9.1 PAY ATTENTION

When the red range
gauge while operating,
temperature.
12.9.2 METHOD
FOR OPERATION
TO GAUGES
lights on the power train oil temperature
reduce load and wait for lowering
of
OF USING STEERING CLUTCH
If the steering clutch one side is used frequently

or if many
gradual turns are made with steering clutch half-engaged,
the
steering clutch will wear out in a short time. Design the travel road
well and steer the machine properly.
12.9.3 PERMISSIBLE
WATER DEPTH
When operating in water, always keep top surface @ of the track

frame 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.
12.9.4 PRECAUTIONS
WHEN TRAVELING
UP OR DOWN
HILLS
Method of using decelerator
pedal
When stepping on the decelerator
pedal while going uphill,
climbing
ability
will be reduced
and the machine
will stop.
Furthermore,
the engine sometimes will stall.
Use engine as brake
When going downhill, shift gear shift lever into low speed to run
engine at slow speed and travel down slope using the engine as a
brake.
Do not move the joystick to the N position.
When traveling down hills of more than 15, shift down to 1st
speed (RI or Fl).
Braking when traveling downhill
While descending a slope using the engine as a brake, also apply
the brakes.
Failure to brake may result in overrunning,
causing engine
trouble.
2-74
12.9.5 PRECAUTIONS
ON SLOPES
Be careful of fuel level

If the fuel level in the
slopes, the engine may
machine or the swaying
stop, so be careful not to
too low.
fuel tank becomes low when working on

suck in air because of the angle of the
of the machine. If this makes the engine
let the fuel level in the fuel tank become
Be careful of oil level

When operating machine on sloped areas of more than 20, fill
every place with oil to H level.
Precautions when engine stops on slopes
If the engine
stops while working
or traveling
on a hill,
immediately
depress the brake pedal to bring the machine to a
complete stop.
12.9.6 METHOD
OF USING BRAKES
The following actions cause premature damage to the brakes, so

avoid such operations.
o
Using emergency brake at full speed
o
Using brake with engine running at full speed in first gear
(Fl, RI) (Machine stall condition)
REMARK
Always depress the decelerator
before actuating the brakes.
pedal to lower the engine speed
2-75
12.9.7 IT IS PROHIBITED TO KEEP THE DOOR OPEN

DURING OPERATIONS (MACHINES EQUIPPED
WITH CAB)
Always keep the door closed when traveling
operations. If the door is left open, there is danger
obstacles or strong vibration.
or carrying out
of damage from
12.9.8 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN

ANY WAY THAT WILL OBSTRUCT THE VIEW
l
l
For safety reasons, do not install anything to the cab glass that
will obstruct the view.
Always keep the glass clean to ensure safety during operations.
12.9.9 PRECAUTIONS FOR BLIND SPOTS CAUSED BY

CAB STAY AND ROPS STAY
&b WARNING
The cab stay and ROPS stay cause blind spots.
When operating, always be sure to check carefully that there is
no obstacle or worker in the surrounding area.
2-76
12. OPERATION
12.10 WORK POSSIBLE
USING
BULLDOZER
In addition to the following, it is possible to further

range of applications
by using various attachments.
increase the
12.10.1
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.
With the dual tiltdozer, the angle of the blade cutting edge can
be changed, so the angle of the cutting edge can be adjusted during
the digging operation to improve the efficiency of the work.
12.10.2
INTO HARD OR FROZEN GROUND

OR DITCHING
CUlTlNG
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.
If the ground is harder, use a ripper attachment
for better
efficiency.
I
12.10.3
FELLING TREES, REMOVING
AE208780
STUMPS
NOTICE
Do not up root trees or stumps or fell trees by angling or tilting
the blade.
For trees with a diameter of 10 - 30 cm (3.9 - 11.8 in), raise the
blade high and push 2 or 3 times to fell the tree.
Next, travel in reverse, and dig the corner of the blade into the
ground to cut and dig up the roots.
When doing this, never hit the tree at high speed or apply shock
to fell the tree.
12.10.4
l
PUSHER OPERATIONS
When carrying out pusher operations,

always install a pusher
plate.
When approaching
the other machine, depress the decelerator
pedal to reduce the engine speed and approach slowly. After
coming into contact, raise the travel speed slowly and push with
full power.
AE208EOO
2-77
12. OPERATION
12.10.5
SMOOTHING
NOTICE
Avoid smoothing
blade.
on rocky or stony ground.
It can damage
the
When finishing the ground surface to a smooth finish after

digging or filling operations, keep a full load of soil in the blade and
operate the blade up or down in small movements while traveling
forward. When leveling windrows or ruts left by the tracks, set the
blade to the FLOAT position, travel at low speed in reverse and drag
the blade over the ground surface.
2-78
12. OPERATION
12.11 RIPPER OPERATION

12.11.1
EFFECTIVE METHOD
The optimum
perpendicular
OF USE
K+P5
digging angle for the shank is when the shank is

to the ground (ripping angle: 45- 50).
In comparatively
soft rock (seismic velocity: 1500 m/s or below),
it is also possible to carry out ripping with the shank tilted to the
rear.
AE105480
On comparatively
hard rock, if ripping is carried out with the
shank tilted to the rear, there will be excessive wear of the point
of tip 0, and the self-sharpening
ability will be lost.
During ripping operations, if the shoes slip because of boulders
or resistance from the bedrock, use the tilt cylinder.
When picking up a stone, advance the machine at a fixed gear
speed (Fl or F2).
AE105490
REMARK
When raising boulders or digging up rockbed, do not put the
transmission
in neutral. If the transmission
is in neutral, the reaction
of the tilt cylinder will push the machine back. Always operate the
machine with the transmission
in FORWARD.
REMARK
Choosing a suitable ripper point to match the type of rock is one
of the most important elements in using the ripper effectively.
Ripper points are available for different types of rock, so select
the most suitable ripper point from the list. For details, see 30.
PROCEDURE FOR SELECTING RIPPER POINT.
2-79
12. OPERATION
12.11.2
DIGGING
UP BOULDERS OR ROCKBED
During ripper operations, if stubborn boulders or rockbed cause

the travel speed to become slower, operate the tilt cylinder to dig up
the boulder/rockbed.
12.11.3
OPERATING
ON SLOPES
When using the variable ripper,

cylinder to select dimension
L.
adjust
the
length
of the tilt
12.11.4
TANDEM
i_'
AE208840
OPERATION
When it is impossible for one machine to carry out ripping under

its own power, ripping can be carried out in tandem.
AE208860
2-80
12.11.5
1.
2.
METHOD
OF OPERATING
PIN PULLER
This is used only on machines equipped with a giant ripper.

Stop the machine in a safe place and lower the shank to the
ground.
Operate the pin puller controller switch to the PULL OUT position
and remove the mounting pin.
I
3.
Move the ripper up or down to set to the desired shank position.
AE20d218
Top surface
De pth
Align with
surface of
4.
Operate the pin puller control switch to insert the mounting pin.
If the pin does not match the position of the hole in the shank,
set the pin puller control switch to the PUSH IN position and
slowly move the ripper up or down.
REMARK
When raising the pin position to increase the digging
a long protector to prevent wear of the shank.
.,,/&,
Push
depth, use
in
AE20094B
2-81
12. OPERATION
12.12 ADJUSTMENT
OF WORK EQUIPMENT
a
WARNING
When adjusting, it is dangerous if the work equipment is moved

by mistake. Set the work equipment
in a safe condition, then
stop the engine and lock the work equipment securely with the
safety lock.
12.12.1
TILTING
BLADE ADJUSTMENT
THE TILTDOZER
NOTICE
The maximum
amount of tilt is 1065 mm (3.5 f-t). (When
semi-U blade is used.)
Be sure not to exceed 1065 mm (3.5 ft) for the tilt.
the
The tiltdozer can be tilted by manipulating the blade control lever

as indicated below.
Tilting adjustment to the right: 650 mm (2.1 ft) or more
Tilting adjustment to the left: 650 mm (2.1 it) or more
(When the semi-U blade is used.)
When a larger tilting adjustment is required, proceed as follows:
By turning brace @I with handle bar @ secured to the L.H. brace,
the blade can be tilted up to the max. adjustment of 1065 mm (3.5
ft) by changing the length of the brace (!I).
Standard distance (!J) between joints is 1552 mm (5.1 ft).
ADJUSTING
SHIM
IN BLADE CYLINDER
CAP
Set the standard shim adjustment in the blade cylinder cap to 4

mm (0.16 in).
Remove shims to balance the wear of the cap and the ball at the
end of the piston rod.
The proper clearance to be maintained with the shims is 0.2 to
0.5 mm (0.008 to 0.02 in).
PIE200378
2-82
ADJUSTING
BRACE
WARNING
If maintenance
is carried out with the engine running, always
have one worker sitting in the operators seat while another
worker carries out the maintenance. Both workers must mutually
confirm the safety during the operation.
Start the engine and use inching control to tilt to the left and
right. Adjustment
can be carried out easily by rotating the brace
handle while raising and lowering.
l
When extending the brace
Set the blade at FLOAT and rotate the brace handle to adjust.
REMARK
When operated in this way, the blade is tilted, so the handle
gradually becomes heavier. When this happens, return the blade
from the tilt position to the horizontal position and turn the handle
again according to the procedure given above.
SHIM ADJUSTMENT
Adjust the thickness of shim so that the ball joint play (7 points)
in the axial direction (shown by the arrow) does not exceed 1 mm
(0.04 in).
Remove
shim @ and tighten
bolts @ to eliminate
the ball joint
play.
Measure
clearance
A and remove
bolts 0.
Install shim @ having its thickness of A mm to A + 1 mm

(A in. to A + 0.04 in) in place with bolts 0.
Confirm that ball joint can move smoothly
after tightening
bolts.
AE20928C
1
2-83
12. OPERATION
12.12.2
ADJUSTING
ADJUSTING
Mounting
according to
bottom hole,
top hole.
RIPPER
DIGGING DEPTH
pin holes are provided in the shank and these are used
the desired digging depth. For normal use, use the
and when particularly deep digging is needed, use the
To change the digging depth, do as follows.

1. Place a pointed object on the tip of pin 0, then hit with a hammer
to remove from the opposite side.
2.
Remove
pin @ and change
the position
of the shank hole.
3.
Insert pin @ partially
The pin is made of one piece, so insert it partially by hand then

knock it in with a hammer.
When a giant ripper is installed, use the pin puller.
For details, see 12.15.4 METHOD OF OPERATING PIN PULLER.
by hand then knock it in with a hammer.

AD052740
REPLACING POINT AND PROTECTOR

To protect the shank, if the protector and point installed to the
tip are worn, replace them.
Place a pin remover on the pin marked by the arrow, then hit
with a hammer to remove from the opposite side.
REMARK
The pin is a unitized type, so insert the pin partially
knock it in fully with a hammer.
2-84
by hand, then
AL116090
12. OPERATION
12.13 EFFECTIVE
SYSTEM
USE OF MODE SELECTION
Lock
UD mode
switch
Economy
selector
mode
switch
Slow
reverse mode
selector
switch
Shoe
mode
slip
se\
switch
Rock
selection
mode
Selector
switch
Selecting the mode to match the type of work and quality of rock
or soil makes it possible to carry out operations effectively.
When all the mode selection switches are OFF, the selection is
suitable for conventional
digging and dozing of bedrock. When
carrying out special rock-crushing operations, it is possible to turn
all the mode switches ON when the starting switch is turned ON, so
please contact your Komatsu distributor for advice.
It is impossible to use any combination
of the lock-up mode and
any other mode.
The economy mode, reverse slow mode, and shoe slip control
mode can be used independently
or in combination.
2-84-l
12. OPERATION
12.13.1
SELECTION
OF MODE
1. DOZING OPERATIONS
LOCK UP MODE
l
l
Speed ranges that can be used: All speed

Applicable operations: Dozing loose soil
ranges
When the lock up mode is turned ON, direct drive or torque

converter drive are automatically
selected according to the load.
AW22525B
ECONOMY MODE
l
l
ON
Speed ranges that can be used: Fl

Applicable operations: Hauling after ripping, dozing blasted rock
When the economy
mode is turned ON, it is automatically
set to
0
ECONCW
MODE
1 2
0 0
[Il.
Carry out dozing operations in this condition, then set to 121 and
carry out operations. From this test, select the matching that gives
power and low shoe slip ratio (frequency of deceleration operation).
Mode [II is set to approx. 90% of full power and mode [21 is set
to approx. 70%.
ON
AW22526E
2. RIPPING OPERATIONS
SHOE SLIP CONTROL
Speed ranges that can be used: Fl
Applicable operations: Ripping
When the shoe slip control switch is turned ON, the rock selection
mode is automatically
set to [31.
Carry out operations in this condition, and if the shoe slip ratio
is too high, press a switch in the hard direction to set the mode to
[41 or 151. If the shoe slip ratio is low and there seems to be lack of
power, press the switch in the soft direction to set the mode to [21
or [Il.
l
l
REMARK
With the shoe slip control, after the gearshift lever is shifted to
Fl, the machine will start to move when the ripper lever is operated
to LOWER or TILT, so there is no need to turn the switch ON/OFF
when carrying out dozing and ripping operations in turn.
2-84-2
SHOE SLIP
CONTROL
12345
00000
AW225270
3.
l
l
SLOW REVERSE MODE

Speed ranges that can be used: RI, 2, 3
Applicable operations: Traveling on bedrock
This is used when

dozing bedrock.
traveling
in reverse
after
ripping
II
or when
The travel speed in reverse slow mode is set to approx. 80% of

the full travel speed.
When using the economy mode and shoe slip control mode
together, the travel speed differs according to each mode.
With shoe slip control, the travel speed in modes [I] - [5] is set
to approx. 85 - 65% of the full travel speed.
I=
I II
SLOW
REVERSE
MOOE
ON
/I/
2-84-3
12.13.2
PROCEDURE FOR SELECTING

WORK
Use the table
below
to select
the
mode
Nature and needs of operation
MODE ACCORDING
that
matches
Operation
the
nature
TO NATURE OR NEEDS OF
or needs
of the operation.
Name of mode to select
of system and effect
By locking up the torque converter and

using direct drive, the effective
transmission
of power is increased and
the oroduction oer unit of fuel is further
1imoroved.
needed even if
the type of rock
or soil changes
The engine output is set specially for

dozing (modes 1 or 2) to give both
power and fuel saving. With this mode,
the following can be achieved:
@ Reduction in frequency of deceleration
operations
_ - @ Reduction in shoe slip
@ Reduction in fuel consumption
L Both power and

_ good fuel
consumption
are
needed
~
No operator
fatigue even when
operating for long
hours
~
Economy mode (~1

[Two modes are
available to match the
type of rock or soil]
The reverse speed is lowered when

-traveling
on bedrock to improve the ride
for the operator.
The reverse speed is lowered when

traveling on bedrock to improve the ride
for the operator.
The following items are always detected:

(1) Engine output
_ (2) Drawbar pull
(3) Shoe slio ratio
If any of these values goes too high, the
Easy to operate
engine output is automatically
controlled
I
I
to the optimum for the actual operation.
As a result, the following are achieved:
@ No need for deceleration
operations
Both power and reduced fuel
@ No need for the operator to watch
consumption
are desired
for shoe slippage
@ Reduction in shoe slippage
In addition, a selection of five modes is
available to cover a wide range of rock
Low repair costs for underconditions (hardness). The power can be
carriage
selected to match the type of rock, so it
is possible to achieve both power and
reduction in fuel consumption.
H
Ripping
No operator fatigue even

when operating for long
hours
Shoe slip control

(%)
mode
(~4: The dozing economy mode, reverse slow mode, and ripping shoe slip control mode
can all be selected independently
or in combination.
In addition, it is possible to
select and correct as needed, so it is possible to achieve precise matching for various
types of operation.
2-84-4
12.14 PARKING
MACHINE
Machines
Depress
with
CatI
WARNING
Avoid stopping suddenly. Give yourself ample room when

stopping.
When stopping the machine,
select flat hard ground and
avoid dangerous places. If it is unavoidably necessary to park
the machine on a slope, place the parking lever in the LOCK
position and insert blocks underneath the track shoes. As an
additional safety measure, thrust the blade into the ground.
control lever is touched by accident,
the work equipment
may move suddenly, and this may lead
Before leaving the operators
seat,
always operate the safety lever to place it securely at the
LOCK position.
1.
eauimed
Machines
eouimed
with
CanODY
brake pedal Q) to stop the machine.
NOTICE
If the brake is depressed when the engine speed or travel speed
is high, the brake disc may make a slipping sound. Normally,
depress decelerator pedal @ to reduce the engine speed and travel
speed before depressing the brake.
ADO53830
2.
Place joystick @ at the neutral

to 1st.
position
and set the speed range
AE208750
2-85
12.
OPERATION
3.
Operate
parking
lever
@ to lock the brakes.
AD051665
4.
Operate blade control lever

LOWER position,
and lower
5.
Set blade
position.
6.
Lock blade control

lever 0.
control
@ and ripper control

the blade and ripper
lever @ and ripper control lever @ to the HOLD
lever @ and ripper
12.15 CHECK AFTER FINISHING

1.
lever @ to the
to the ground.
control
lever @ with safety
WORK
Use the meters and caution

lamps to check the engine water
temperature,
engine oil pressure, fuel level and power train oil
temperature.
2-86
12.16 STOPPING
ENGINE
Machines
eauiDDed
with
Cab
Machines
eauimed
with
CanoDY
NOTICE
If the engine is abruptly stopped before it has cooled down,
engine life may be greatly shortened. Consequently,
do not abruptly
stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly stop
it but run it at low speed to allow it to cool gradually, then stop it.
1.
Place fuel control lever @ in the low idling position and run the
engine at low idling speed for about 5 minutes to allow it to
gradually cool down.
AE20983E
2.
Push fuel control

the engine.
lever @ in the engine
stop position
and stop
3.
Turn the key in starting switch @to the OFF position and remove
the key.
OFF
A0051781
2-87
12. OPERATION
12.17 CHECK AFTER STOPPING
ENGINE
1. Walk around the machine and check the work equipment,

paintwork, and undercarriage,
and check also for leakage of oil or
water. 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 stuck to the undercarriage.
12.18 LOCKING
To prevent vandalism, there are locks at the following
places.
Places that can be locked with the starting switch key.
l
Right and left engine side cover 0 (left side: 3 places, right side:
2 places)
l
Electrical component
box inspection cover (left) @
l
Cab door opener @
l
Cap with lock @
l
Radiator cap
l
Fuel tank cap
l
Hydraulic oil tank cap
0
Power train oil filler cap
l
Battery inspection cover @
l
Tool box inspection cover @
Commercially
places.
l
2-88
available
Power train centralized

inspection cover 0
locks can
pressure
be fitted
detection,
to the
following
power train oil level
AE209260
12. OPERATION
12.19 TIPS FOR LONGER
UNDERCARRIAGE
LIFE
Undercarriage
life greatly varies depending on operation method,
inspection and maintenance.
For most efficient operation, keep the
following point in mind.
12.19.1
OPERATION
METHOD
Select the track shoe that best suits the type of soil to be
encountered
in service.
Please consult your Komatsu distributor when selecting track
shoes.
Do not allow shoe slipping to occur during operation.
slipping occurs, reduce load to the blade until slipping
Avoid sudden starts, acceleration
speeds and sharp turns.
If shoe
stops.
or stops, unnecessarily
high
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.
Prior to operation,
clear boulders and obstacles
machine from riding over them while operating.
to
prevent
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 toward the top of
the slope.
When ground inclines to left or right during digging operation,

do not continue to dig with machine inclined. Move machine
back to level ground and start to dig again.
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.
2-89
12.
OPERATION
12.19.2
INSPECTION
AND ADJUSTMENT
Clearance
Properly adjust track tension.

Tension should be measured
at clearance
@ shown in the
diagram - usually 20 to 30 mm (0.8 to 1.2 in) at this point. For
rocky terrain, tighten tracks slightly. In clay or sandy areas,
slightly loosen them. (For inspection
and adjustment
procedures, refer to 24.2 WHEN REQUIRED).
AE200958
Check idler rollers for oil leakage as well as for loose bolts and
nuts. If any trouble is detected, repair immediately.
Check the clearance between the idler guide plate and the track
frame. If clearance @ increases, idler may develop side motion
and tracks may come off. (For inspection and adjustment procedures, refer to 24.2 WHEN REQUIRED.)
I
12.19.3
INSPECTION
ADO52850
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 periodical
inspection and contact the Komatsu distributor in your area when
machine has approached
repairable limits and reversing limits.
MEASURING
HEIGHT OF GROUSER
After taking up slack in track shoes, measure
shoe as shown below.
Standard height (h): 93 mm (3.7 in)
Repair limits-30
mm (1.2 in)
height at center of
h
L
\I
7
AE105710
MEASURING
OUTSIDE DIAMETER OF TRACK ROLLER
1. Measure height (size C) of link tread as shown.
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):
A=(B-C)x2
Standard size (A): 270 mm (IO.6 in)
Repair limits: 234 mm (9.2 in)
AE105720
2-90
13. TRANSPORTATION
When transporting
the machine, observe
regulations, and be careful to assure safety.
all related
laws and
13.1 LOADING, UNLOADING WORK
WARNING
Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely loaded and unloaded.
If the ramp sags appreciably,
reinforce it with blocks, etc.
When loading and unloading the machine, park the trailer on
a flat firm roadbed. Keep a fairly long distance between the
road shoulder and the machine.
Remove the mud from the undercarriage
to prevent the
machine from slipping to the side on slopes.
Be sure the ramp surface is clean and free of grease, oil, ice
and loose materials.
Never change the direction of travel when on the ramps. If it
is necessary to change direction,
drive off the ramps and
correct the direction, then drive on to the ramps again.
Do not use the counterrotation
turn.
When loading or unloading, always use ramps or a platform and
carry out the operations as follows.
Properly apply the brakes on the trailer and insert blocks beneath
the tires to ensure that it does not move. Then fix the ramps in
line with the centers of the trailer and the machine.
CORRECT
Blocks
Distance
between
ramps
Set the machine in line with the ramps, then load or unload the
machine at slow travel.
Load the
trailer.
machine
correctly
in the
specified
position
on the
2-91
13.2
PRECAUTIONS
FOR LOADING
After loading to the specified

follows.
1. Lower the blade slowly.
position,
secure the machine
as
2.
Lock all the control
3.
Set the parking
4.
Move the fuel control lever to the low idling position and turn
the starting switch key to the OFF position to stop the engine.
Remove the key.
5.
Lock the cab door, left and right engine

battery inspection cover.
6.
Put blocks under the front and rear of both tracks and secure the
machine in position with chains or wire rope of appropriate
strength to prevent the machine from moving during transportation. Be particularly careful to tie the machine down securely
so that it does not slip to the side.
13.3
METHOD
levers securely
with the safety lever.
lever to the LOCK position.
OF LIFTING
side covers,
and the
MACHINE
WARNING
Never raise the machine with any worker on it.

Always make sure that the wire rope used for lifting the
machine is of ample strength for the weight of the machine.
Never try to lift the machine in any posture other than the
posture given in the procedure below. There is danger that
the machine may lose its balance.
When lifting the chassis, pay attention to the center of gravity
and be careful to maintain the balance.
When lifting the machine,
flat ground.
carry out the operation
as follows
or
1.
Stop the engine and be sure to set the parking lever to the LOCk
position.
2.
Set the lifting position for the machine

on the right.
as shown
AE105730
in the diagran
NOTICE
This description of the method for lifting the chassis applies tc
standard specification
machines.
Depending on the attachments and options installed, the methoc
of lifting will differ. In such cases, please contact your Komatsi
distributor for advice.
For details
2-92
of the weight,
see 25. SPECIFICATIONS.
AE10-5740
13. TRANSPORTATION
13.4
PRECAUTIONS
FOR TRANSPORTATION
Blo lck
account
the width,
height
and weight
Block
of the machine.
Obey all state and local laws governing the weight, width and
length of a load. Observe all regulations governing wide loads.
AE20043B
I
13.5
REMOVAL OF CAB (MACHINES

WITH CAB)
AEl05760
EQUIPPED
If it is necessary to remove the cab for transportation,

disconnect
the washer hoses, cab wiring, and washer motor wiring before
removing the cab.
1. Push the grommet portion from the hole in the machine cover
towards the cab, then remove.
2.
Disconnect 4 washer
pin plug x I).
hoses and the wiring
(single wires x 2, 4-
REMARK
l
After removing,
cover the washer hoses with a vinyl bag to
prevent any dirt or dust from entering.
l
Before removing the cab, measure the clearance between the
cab and each lever (joystick and blade control lever, etc.). Note
the measurements
to use as a standard when installing the cab
again.
Red-Right
Blue-Left
Black
Rear
Colorless-Front
View
From
Y Red(back
ooewr
fuse
door
door
window
window
box
UD
source)
AE20810B
2-93
13. TRANSPORTATION
13.6
INSTALLATION
OF CAB
install the cab parts in the opposite order to removal.

Connect all parts that were disconnected.
1.
Install the cab mounting bolts as follows.

Lower the cab slowly on top of the floor frame.
2.
Align the cab with the floor frame, then install bolts and washers
in holes @ - 0.
Do not screw the bolts in fully. Screw them in 3 or 4 turns.
3.
Tighten
Tighten
the bolts in holes Q - @ fully.

in the order 0, 0, 0, 8, @, 0,
Tighten
bolts @ - @ fully.
4.
@, @
2-94
AE209290
14. COLD WEATHER OPERATION
14.1
PRECAUTIONS
FOR LOW TEMPERATURE
If the temperature
becomes low, it becomes difficult to start the
engine, and the coolant may freeze, so do as follows.
14.1.1
FUEL AND LUBRICANTS
Change to fuel and oil with low viscosity for all components.
For details of the specified viscosity, see 20. USE OF FUEL,
COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.
14.1.2
COOLANT
WARNING
-A
-,
Keep antifreeze fluid away from an open flame.

when using antifreeze.
NOTICE
Never
use methanol,
ethanol
or propanol
Never smoke
based antifreeze.
Where no permanent antifreeze is available, an ethylene glycol

antifreeze without corrosion inhibitor may be used only for the cold
season. In this case, clean the cooling system twice a year (in spring
and autumn). When refilling the cooling system, add antifreeze in
autumn, but do not add any in spring.
Absolutely avoid using any water leak preventing agent irrespective of whether it is used independently
or mixed with an antifreeze.
Do not mix one antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant,
see 24.2 WHEN REQUIRED.
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the standard requirements as shown below. With permanent
antifreeze, no change of
coolant is required for a year. If it is doubtful that an available
antifreeze meets the standard requirements,
ask the supplier of that
antifreeze for information.
Standard requirements
for permanent antifreeze.
l
SAE . .. . .. . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . .. .. . .. . . . .. . . . . . . .. .. . . . . . . .. . . . . . .. . .. . . . . . . . . .. . J1034
l
FEDERAL STANDARD . . .. . .. . . . . . . .. . . . . . .. . .. . . . . . .. . . . . . . .. . .. . . . . . .. O-A-548D
2-95
14.1.3
BATTERY
g
WARNING
To avoid gas explosions,
do not bring fire or sparks near the
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.
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
lOO%, and insulate it against cold temperature
so that the machine
can be started easily the next morning.
Measure the specific gravity and calculate
from the following conversion table.
100%
90%
80%
75%
1.28
1.26
1.24
1.23
1.29
1.27
1.25
1.24
1.30
1.28
1.26
1.25
the rate of charge
1.31
1.29
1.27
1.26
REMARK
When adding distilled water in cold weather,
add it before
starting operations in the morning to prevent the electrolyte from
freezing.
2-96
14.2
AFTER COMPLETION
OF WORK
To prevent mud, water, or the undercarriage

from freezing and
making it impossible
for the machine to move on the following
morning, always observe the following precautions.
Mud and water on the machine body should be completely
removed. This is to prevent damage to the seal caused by mud
or dirt getting inside the seal with frozen drops of water.
Park the machine on concrete or hard ground. If this is impossible, park the machine on wooden boards.
Open the drain valve and drain any water collected in the fuel
system to prevent it from freezing.
As the battery capacity drops markedly in low temperatures,
cover the battery or remove it from the machine, keep it in a
warm place, and install it again the next morning.
14.3
AFTER COLD WEATHER
When season changes and the weather becomes warmer, do as

foliows.
Replace the fuel and oil for all parts with oil of the viscosity
specified.
For details, see 20. USE OF FUEL, COOLANT AND LUBRICANTS
ACCORDING
If for any reason permanent antifreeze cannot be used, and an
ethyl glycol base antifreeze (winter, one season type) is used
instead, or if no antifreeze is used, drain the cooling system
completely,
then clean out the inside of the cooling system
I,
thoroughly,
and fill with fresh water.
When it is unnecessary to use the automatic starting aid (APS)
(when the ambient temperature
is above 15C), always keep the
fuel valve closed.
2-97
15. LONG-TERM
15.1
STORAGE
BEFORE STORAGE
When putting the machine in storage for more than one month,
do as follows.
After washing and drying each part, store the machine indoors.
If it has to be left outdoors, choose a flat place where the
machine will be safe from flooding or other problems, and cover
the machine.
Completely
storage.
fill the fuel tank, lubricate
and change the oil before
Apply a thin coat of grease to metal surface

piston rods and the idler adjusting rods.
of the hydraulic
Disconnect the negative terminals of the battery and cover it, or

remove it from the machine and store it separately.
If the ambient temperature
is expected to drop
always add antifreeze to the cooling water.
below
OT,
Place all control levers at the neutral position, set the safety lever
and parking brake lever to the LOCK position, and set the fuel
control lever to the low idling position.
15.2
DURING
STORAGE
dk
WARNING
If it is unavoidably
necessary to carry out the rustpreventive
operation
while the machine is indoors, open the doors and
windows
to improve ventilation
and prevent gas poisoning.
l
Operate the engine and move the machine for a short distance
once a month so that a new film of oil will be coated over
movable parts and component surfaces. At the same time, also
charge the battery.
Before operating the work equipment,

hydraulic piston rod.
2-98
wipe off the grease on the
15. LONG-TERM STORAGE
15.3
AFTER STORAGE
NOTICE
If the machine is stored without carrying out the monthly rust
prevention operation, request your Komatsu distributor for service.
Carry out the following
of long-term storage.
l
l
procedure
when taking the machine
Wipe off the grease from the hydraulic

Add oil and grease to all places.
cylinder
out
rods.
2-99
16. TROUBLESHOOTING
16.1
AFTER RUNNING
OUT OF FUEL
When starting 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 24.5 EVERY 500 HOURS
SERVICE.
16.2
METHOD
OF TOWING
a
l
l
MACHINE
WARNING
When towing the machine, use a wire rope that has ample
strength for the weight of the machine being towed.
A shackle must always be used when using a towing hook.
The wire rope should be horizontal and at a right angle to the
track frame.
Move the machine slowly.
AE207710
If the machine sinks in mud and cannot get out under its own
power, or if being used to tow a heavy object, fit the wire to the
towing hook as shown in the diagram on the right, or in the case of
machines with a drawbar, fit the wire to the drawbar pin when
towing.
Permissible load for towing hook: 48500 kg (475623 N)
Always carry out towing operations within the specified range
for the permissible load.
WARNING
When checking or handling the battery, stop the engine and

turn the starting key to the OFF position before starting.
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 dilute sulphuric acid, and it will attack
your clothes and skin. If it gets on your clothes or on your
skin, wash it immediately
off with large amounts of water. If
it gets in your eyes, wash it out with fresh water, and consult
a doctor.
When removing the battery, first disconnect the cable from
the ground (normally, from the negative 0 terminal). When
installing, install the positive @terminal
first. If a tool touches
the cable connecting the positive terminal and the chassis,
there is danger that it will cause sparks.
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.
2-100
disconnect the
cable from the
16. TROUBLESHOOTING
16.3.1 STARTING
When
starting
ENGINE WITH BOOSTER CABLE

the engine
with a booster
cable, do as follows:
REMOVAL, INSTALLATION
OF BATTERY CABLE
1. Open battery cover 0.
2. Before removing the 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 nut of the terminal
and
remove the wires from the battery.
3. When installing the battery, connect the ground cable last.
Insert the hole of the terminal on the battery and tighten the nut.
Tightening torque: 5.9 - 9.8 Nm (0.6 - 1.0 kgm, 4.3 - 7.2 Ibft)
4. Close battery cover 0.
PRECAUTIONS
WHEN
BOOSTER CABLE
CONNECTING
AND
DISCONNECTING
WARNING
When starting the engine from another machine, connect the

batteries in parallel.
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 engine block of the
problem machine, but sparks will be generated when this is
done, so connect to a place as far as possible from the
battery.
Use care when removing the cables from the machine that
has been started. Do not allow the cable ends to contact each
other or the machine, to avoid hydrogen explosion.
NOTICE
l
The size of the booster
battery size.
cable and clip should be suitable
AD052960
for the
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
Make
or corrosion.
sure that the cables and clips are firmly
connected.
2-101
CONNECTING
THE BOOSTER CABLES
Keep the starting
switch
at the OFF position.
Connect the booster cable as follows, in the order of the numbers marked in the diagram.
1. Make sure that the starting switches of the normal machine and
problem machine are both at the OFF position.
Engine
block
the
Drobiem
2.
Connect one clip of booster cable @ to the positive @ terminal

of the problem machine.
3.
Connect
terminal
4.
Connect one clip of booster cable @ to the negative

of the normal machine.
5.
Connect the other clip of booster cable @ to the engine

the problem machine.
the other clip of booster

cable
@ to the positive
of
macnine
AE20460B
0 terminal
block of
STARTING THE ENGINE

1.
Make sure the clips are firmly connected
2.
Start the engine of the normal

idling speed.
3.
Turn the starting switch of the problem machine to the START

position and start the engine. Refer to 12.2 STARTING
ENGINE.
DISCONNECTING
machine
to the battery terminals.

and keep it to run at high
THE BOOSTER CABLES
After the engine has started, disconnect the booster cables in the
reverse of the order in which they were connected.
1.
Remove one clip of booster cable @ from the engine block of the
problem machine.
2.
Remove
terminal
3.
Remove one clip of booster cable @from

4.
Remove
terminal
2-102
the other clip of booster cable @I from the negative

the positive @terminal
the other clip of booster cable @ from the positive

of the problem machine.
Engine
block
tne
DrOblem
of
machIne
PiE204BlB
16. TROUBLESHOOTING
16.4
OTHER TROUBLE
1: Always contact your Komatsu distributor when dealing with these items.
In cases of abnormalities or causes which are not listed below, please contact your Komatsu
distributor for repairs.
.
l
16.4.1 ELECTRICAL SYSTEM

Problem
Main causes
Lamp does not glow brightly even

when the engine runs at high speed
Remedy
Defective
wiring
Defective
tension
adjustment
Charge lamp does not go out even

when engine is running
l
l
Defective
Defective
alternator
wiring
(0 Replace)
(o Check, repair)
Abnormal
alternator
Defective
alternator
(o Replace)
Defective
wiring
lnsufticient
battery
charge
Insufficient
battery
charge
Insufficient
charge
Defective
Defective wiring
Insufficient battery
a
a
Defective
Defective
Defective monitor lamp

Disconnection
in glow plug
to Replace)
to Replace)
Blown fuse
Low battery
Lamp flickers while
Starting
starting
is running
noise is generated
motor
switch
motor
motor turns
Starting motor
engine starts
Preheating
light up
keeps going
engine
disengages
monitor
sluggishly
before
lamp does not
(When the temperature

cooling water exceeds
condition is normal)
Air conditioner
from
does not turn when

is turned to ON
Pinion of starting
in and out
Starting
engine
of the engine
20X, this
operation
of fan belt
is defective
l
l
l
Blade does not pitch when pitch

operation is carried out (dual tilt
specification
machine only)
battery
starting
(e Check, repair loose terminals,

disconnections)
l Adjust fan belt tension
For details, see EVERY 250
HOURS SERVICE
(o Check, repair)
Charge
Charge
Charge
to Replace)
motor
l
l
charge
wiring
timer
(Check,
Charge
repair)
(o Check, repair)
to Replace)
(a Check,
charge
Defective
Defective
air conditioner
blower switch
Defective
compressor
a
a
Defective
Defective
wiring
switch
Defective
solenoid
valve
switch
repair)
Charge
(o Replace
air conditioner
(o Replace blower
(o Replace)
switch)
switch)
(o Check, repair)
(o Replace)
(a Replace)
2-103
16.4.2 CHASSIS
Problem
Oil pressure
fails to rise
in torque
Main causes
converter
Remedy
Improper tightening of oil pipe,

pipe joint, air leaking in or oil leaking
out because of damage
Wear, scuffing of gear pump
Insufficient oil in transmission
Clogged oil filter element

transmission
case
Torque
converter
is overheats
Torque
gauge
converter
oil temperature
does not work
Lacks drawbar
(machine
Oil pressure
Lack of flow of lubricant caused

wear of power train gear pump
Defective
Defective
pull
Machine will not move off when

joystick is placed at FORWARD or
REVERSE
Machine doesnt stop when

pedal are depressed
Track comes
Sprocket
steering
brake
off
develops
abnormal
Brake rises too slowly
wear
or does not
is high
too low
by
oil temperature
gauge
contact in wiring connection
moves
Insufficient
2-104
too slowly
force of ripper
fan belt
(o Replace oil temperature

(o Check, repair)
gauge)
Lack of oil in steering
Transmission
oil pressure does not rise
Steering clutch slips
0 Wear, scuffing of gear pump
o Clogged oil strainer element in
steering clutch case
Brake is not applied

pulled
(o Adjust linkage)
(o Check brake pressure)
Defective
Track is too loose
Adjust track tension. For details,

see WHEN REQUIRED.
Track is too loose or too tight
Adjust track tension. For details,

see WHEN REQUIRED.
Lack of hydraulic
Add oil to specified
is too
See Engine related parts

Go to Oil pressure in torque
verter fails to rise
is
brake adjustment
oil
Add oil to the specified level.

For details, see CHECK BEFORE
STARTING
Go to Oil pressure
verter fails to rise
(0 Check, replace)
in torque
Work equipment
position
lock lever is at LOCK
Lack of hydraulic
position
oil
Work equipment
position
lock lever is at LOCK
Leakage
piping
con-
o Clean. For details, see EVERY

1000 HOURS SERVICE
(o Adjust linkage)
(o Check brake pressure)
level. For
details, see EVERY 250 HOURS

SERVICE
from
con-
(o Check, repair)
clutch case
on side which
rise at all
(or blade tilts too slowly)
Ripper
Replace
See Engine related parts

(0 Clean or replace)
l
Go to Oil pressure in torque
converter fails to rise
(o Replace gear pump)
l
Does not steer even when

is operated
in
Lack of engine horsepower

Oil pressure in torque converter
low
Steering clutch is slipping
does not pick up speed)
strainer
repair
Check, replace)
Add oil to the specified level.
For details, see CHECK BEFORE
STARTING
Clean. For details, see EVERY 1000
HOURS SERVICE
case
Loose fan belt

Engine water temperature
Clogged oil cooler
l
l
Check,
Set to FREE position
details, see EVERY 250 HOURS

SERVICE
Set to FREE position
10 Tighten)
level. For
16.4.3 ENGINE
Problem
Main
Engine oil pressure monitor

flashes when engine speed is
raised after completion
of warm-
Engine
(sucking
Clogged
causes
Remedy
oil pan oil level is low

in air)
oil filter cartridge

BEFORE STARTING
Replace cartridge,
SERVICE
up.
l
Steam
is emitted
of radiator
from top part
(pressure
Defective tightening of oil pipe

joint, oil leakage from damaged
part
Defective
Cooling
valve)
caution
water
lamp
level low, water
cooling system
Clogged radiator
fin
Engine does not start when

starting motor is turned
in
cooling system,
Clean or repair,
Exhaust
gas occasionally
turns
black
Abnormal
noise generated
(combustion
or mechanical)
see CHECK
clean inside of
see WHEN
see WHEN
REQUIRED
REQUIRED
Lack of fuel
Add fuel, see CHECK BEFORE

STARTING
motor
cranks
pump
packing
Replace)
Repair place where air is sucked

Replace pump or nozzle)
or
engine
See ELECTRICAL
Adjust
in
SYSTEM
valve clearance)
Too much oil in oil pan

BEFORE STARTING
level, see CHECK
Improper
Change
fuel
Clogged
Defective
Defective
Defective
nozzle
compression
turbocharger
l Clean or replace, see WHEN

REQUIRED
(o Replace nozzle)
(e Adjust valve clearance)
10 Clean or replace turbocharger)
Defective
nozzle
(o Replace
Combustion
noise occasionally
makes breathing sound
repair,
Replace thermostat)
Tighten cap or replace
sluggishly
Defective compression
o Defective valve clearance
or blue
water,
BEFORE STARTING
Replace fan belt
Change cooling water,
Defective thermostat
Loose radiator filler cap (high
altitude operation)
Defective water temperature
monitor
nozzle
Starting
gas is white
lamp)
Add cooling
fin or damaged
Air in fuel system

Defective fuel injection
Exhaust
see EVERY 250 HOURS
repair)
(e Replace
leakage
Loose fan belt
Dirt or scale accumulated
Engine water temperature

monitor remains alight
(o Check,
level, see CHECK
fuel
air cleaner
Low grade
Overheating
element
fuel being
used
l
l
to specified
nozzle)
Change to specified
See item Indicator
fuel
of water
temperature
gauge is in red range on right side of

gauge.
l
l
Damage inside muffler

Excessive valve clearance
(o Replace
(o Adjust
muffler)
valve clearance)
2-105
16.
TROUBLESHOOTING
16.4.4 APS (Automatic Priming System)

Main causes
Problem
Engine
does not start at all.
Nozzle clogging (dust, paraffin

precipitation,
defective nozzle)
Defective glow plug
Fuel pipe collapse, fuel leak,
clogging
Defective wiring
Fuse breaking
Defective
Burner
monitor
is ignited
APS controller
Defective
sensor
to Replace temperature
Deposited
point
APS water
heater
temperature
relay contact
fuel,
10 Check, repair)
(0 Replace)
(0 Replace)
(0
Clean, change to specified

replace nozzle)
Replace)
Replace)
(0
(0
(0
Check, repair
(0
Replace temperature
(0
Replace)
10 Replace
heater
fuel,
or replace)
sensor)
sensor)
relay)
and preheating
lamp remaining
lighted.
Preheating monitor lamp does

not become bright (when the
temperature
of the engine
cooling water exceeds ZOC,
the engine preheating system
is in normal condition)
Disconnection
l
l
air heater and glow plug

Defective wiring
Defective timer
Burner
Glow
Fuel is not or less sprayed.

o Nozzle clogging (dust, paraffin,
precipitation,
defective nozzle)
is not ignited
Z-106
10 Clean, change to specified

replace nozzle)
(0 Replace)
10 Check, repair)
Nozzle clogging (dust, paraffin

precipitation,
defective nozzle)
Defective glow plug
Fuse breaking
Alternator functional defect
(Alternator output shortage)
Defective APS water temperature
sensor
Defective APS controller
Engine does start smoothly

but much white smoke emits
or the engine stop.
When loaded, the engine will

emit black smoke and stop.
Remedy
in electrical
plug is not heated
Defective
intake
to Replace)
to Check, repair)
(o Replace)
red.
APS controller
See item Preheating

monitor
does not become bright
(0 Clean, change to specified

replace nozzle)
(o Replace)
lamp
fuel,
16.5
IF MODE SELECTION
SYSTEM
FLASHES
If the [Electronic system] caution lamp lights up and the caution

lamp flashes, or if it becomes impossible to control the engine speed
with the throttle
lever and decelerator
pedal, stop operations
immediately
and check the LED display on the controller.
Then
contact your Komatsu distributor to ask for repairs.
In addition to the above, if any of the problems in the table below
occur, there is probably some abnormality
in the work equipment
lever switch or transmission
speed range sensor, so please contact
your Komatsu distributor for repairs.
Mode
Problem
Operation
l
l
l
l
Shoe slip control
Ripping
l
l
l
Dozing
Economy
Reverse
slow
Reverse
All operations
Lock-up
Traveling under
own power
l
l
l
l
Power is not restricted when shoe slip occurs

Not possible to control even when shoe slip occurs
Power is slow to recover when slippage stops
Difficult to rip rock by operating lever TILT and RAISE
Travel speed increases when shank penetrates
Travel speed is slow and there is lack of drawbar pull
No feeling of control, engine remains at full throttle or
partial speed
When ripping starts, machine moves suddenly
Engine speed changes, difficult to carry out operation
No feeling of control, engine remains at full throttle or
partial speed
Ripper RAISE speed is slow
Travel speed increases in reverse slow
Lock-up is not actuated
Transmission
shock increases
Engine drops to partial
own power
speed when
traveling
under
2-107
2
II
m
2
P
2
c)
m
3
2
17. GUIDES TO MAINTENANCE
Do not carry out any inspection

Perform
maintenance
and maintenance
operation
that is not given in this manual.
work on hard, flat ground.
Check service meter

Check the service meter
to be carried out.
reading
Komatsu genuine replacement

Use Komatsu
genuine
every day to see if the time has come for any necessary
maintenance
parts:
parts specified
in the parts list as replacement
parts.
Komatsu genuine oils:

Use Komatsu genuine
ambient temperature.
oils and grease.
Choose
oils and grease
with
proper
viscosities
specified
for
Always use clean washer fluid:

Use automobile
window
washer
fluid and be careful
not to let any dirt get into it.
Clean oil and grease:

Use clean oil and grease. Also, keep containers
from oil and grease.
of the oil and grease clean. Keep foreign
materials
away
Keeping the machine clean:

Always keep the machine
grease fittings, breathers
clean. This makes is easier to find parts causing problems. Keep in particular
and oil level gauges clean and avoid foreign matters from getting in them.
Be careful of hot water and oil:

Draining hot oils and coolants and removing
hazardous. Allow the engine to cool.
If the oil has to be drained when it is cold, warm
before draining it.
their
filters
immediately
after
the
up the oil to a suitable temperature
engine
(approx.
stops
are
20 - 40C)
Checking foreign materials in drained oil:

After oil is changed or filters are replaced,
materials. If large quantities
distributor.
of metallic
check the oil and filters for metallic particles and foreign
particles or foreign materials are found, consult your Komatsu
Fuel strainer:
If your machine
is equipped
with a fuel strainer,
do not remove
it while
fueling.
Oil change:
Check or change
oils in the places where
dust is scarce to keep foreign
materials
away from oils.
Warning tag:
Attach the warning tag to the starting switch or other appropriate
is not aware of the circumstances
from starting the engine.
control
lever to avoid someone
Obey precautions:
During the operation,
3-2
always
obey the precautions
on the safety label stuck to the machine.
who
Welding instructions:
l
Turn off the engine starting switch.
e
Do not apply more than 200 V continuously.
e
Connect grounding the cable within 1 m from the area to be welded.
l
Avoid seals or bearings from being between the area to be welded and the position
point.
Fire prevention:
Use nonflammable
oil.
cleaner
or light oil for cleaning
parts. Keep flame
or cigarette
of grounding
light away from light
Clamp faces:
When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings
new ones. Be sure to fit O-rings and gaskets when assembling.
Objects in your pockets:
Keep your pockets free of loose objects which can fall out and drop into the machinery;
you work on the machinery while bending over it.
and gaskets with
especially
when
Checking undercarriage:
When working in rocky areas, check for damage to the undercarriage
and for looseness, flaws, wear and
damage in bolts and nuts. Loosen the track tension a little when working in such areas.
Cleaning machine:
l
Do not direct a high-pressure
jet directly at the radiator.
l
Do not splash water over the electrical equipment.
l
Never spray steam or water directly at the radiator or oil cooler portions.
Controller:
The machine monitor controller may malfunction
if affected by electrical interference from an outside
source, so when installing any radio system to the machine, please contact your Komatsu distributor for
advice.
Checking lubricating oil level:
The lubricating oil level should be neither too high nor too low. When
that the oil at the proper level.
checking
and adding
oil, check
Pre- and post-work

checks:
Before starting work in mud, rain, snow or at seashore, check plugs and valves for tightness. Wash the
machine immediately
after the work to protect components
from rusting.
Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they
are submerged
in water.
Dusty worksites:
When working at dusty worksites, do as follows:
o
Check the air cleaner for clogging more frequently.
Clean the air cleaner at shorter intervals than
specified.
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.
3-3
Avoid
mixing
oils:
Never mix oils of different brands. If you have only oil which is a different brand from the one that is
used in the machine, do not add it but replace all the oil.
Bleeding
air:
After changing the oil, or replacing or cleaning the filter element or strainer, bleed the air from inside
the circuit.
If the oil in the hydraulic tank has been changed, or the element replaced, or the hydraulic cylinders or
work equipment piping have been removed, run the engine at low idling after completion of the
operation to bleed the air as follows.
1. Operate each cylinder 4 - 5 times to a point approx. 100 mm before the end of its stroke.
2.
Next, perate each cylinder to the end of its stroke 3 - 4 times.
If, at first, the engine is run at high speed or the cylinder is operated to the end of its stroke, the air inside
the cylinder may cause damage to the piston packing or other parts.
Precautions
l
when
opening
and closing
engine
side cover:
When standing on the track to open the engine side cover, adopt a standing position, hold the side
cover with both thumbs, and open it slowly with your other fingers.
When the engine side cover is open, do not open or close the cab.
Before opening or closing the cab, always close the engine side cover first.
*II209790
3-4
AE209800
18. OUTLINES OF SERVICE
Use Komatsu
genuine
When
Unless otherwise specified,

shown in the table below.
changing
Item
Engine
oil pan
Power train oil pan

(incl. transmission,
torque converter
and bevel gear
cases)
Damper case
Final drive case
Hydraulic
tank
parts for replacement.
or adding
oil, do not use a different

the oil and coolant
SAE 15W-40
API classification
CD
SAE 30
API classification
CD
SAE IOW
API classification
CD
Fuel tank
Radiator
Komatsu
(AF-ACL)
OUTLINE
used at the time of shipment
from the factory are as
Kind of fluid
ASTM D975 No. 2

(However, ASTM D975 No. 1 is
used for the winter season
(October to March))
18.1
type of oil.
Super Coolant
41% added to water
OF OIL, FUEL, COOLANT
18.1.1 OIL
Oil is used in the engine and work equipment under extremely severe conditions (high temperature,
high pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature
for use given in the Operation
and
Maintenance
Manual. Even if the oil is not dirty, always replace the oil after the specified interval.
Oil corresponds to blood in the human body, so always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from getting in.
The majority of problems with machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
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.
When changing the oil, always replace the related filters at the same time.
We recommend
you to have an analysis made of the oil periodically to check the condition of the
machine. For those who wish to use this service, please contact your Komatsu distributor.
3-5
18.1.2 FUEL
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work
properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance
Manual.
Fuel may congeal depending on the temperature
when it is used (particularly in low temperature
below -15C), so it is necessary to change to a fuel that matches the temperature.
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always
fill the fuel tank after completing the days work.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment
and water from the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from
the circuit.
18.1.3 COOLANT
River water contains large amounts of calcium and other impurities, so if it is used, scale will stick
to the engine and radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.
When using anti-freeze, always observe the precautions given in the Operation and Maintenance
Manual.
Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine
is shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as
it is even in hot areas.
Anti-freeze is inflammable,
so be extremely careful not to expose it to flame or fire.
The proportion of anti-freeze to water differs according to the ambient temperature.
For details of the mixing proportions, see 24.2.1 CLEAN INSIDE OF COOLING SYSTEM.
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating and will also cause problems with corrosion from
the air in the coolant.
18.1.4 GREASE
a
WARNING
Do not carry out greasing when the engine is running.

o
l
3-6
Grease is used to prevent twisting and noise at the joints.

The nipples not included in the maintenance
section are nipples for overhaul, so they do not need
grease.
If any part becomes stiff after being used for a long time, add grease.
Always wipe off all of the old grease that is pushed out when greasing. 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.
18.1.5 STORING
l
l
OIL AND FUEL
Keep indoors to prevent any water, dirt, or other impurities from getting in.
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
sheet or take other measures
to protect them.
To prevent any change in quality during long-term storage, be sure to use in the order of first in _
first out (use the oldest oil or fuel first).
18.1.6 FILTERS
l
o
l
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,
it is necessary to consider replacing the filters at
shorter intervals according to the oil and fuel (sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
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.
Do not open packs of spare filters until just before they are to be used.
Always use Komatsu genuine filters.
18.2
RELATING
TO ELECTRIC SYSTEM
If the wiring gets wet or the insulation is damaged,

in hazardous malfunction
of the machine.
Services relating to the electric system are (I) check of fan belt tension,
in the fan belt and (3) check of battery fluid level.
Never
remove
Never
install any electric
Be careful to keep the electric
When
Never connect
working
or disassemble
any electric
components
on the seashore,
any optional
system
components
system
installed
free of water
when
clean the electric
(2) check of damage
or wear
by Komatsu.
washing
system
source to the fuse, starting
leaks and this could result
in the machine.
other than these specified
carefully
power
the electric
the machine
to prevent
switch,
battery
or when
it rains.
corrosion.
relay, etc.
3-7
19. 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 correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
The parts in parentheses
Item
are to be replaced
Part No.
at the same time.
Part Name
Neight
(kg)
Qty
Engine oil filter
600-211-1231
Cartridge
Transmission filter
07063-o 1142
(07000-05 175)
Element
(O-ring)
Torque converter
filter
07063-01142
(07000-05 175)
Element
(O-ring)
(1)
Fuel filter
600-31 I-8293
Cartridge
Corrosion resistor
600-41 l-l 170
Cartridge
Hydraulic oil filter
07063-o 1142
(07000-05180)
(07000-05195)
Element
(O-ring)
(O-ring)
(I)
(1)
Air conditioner filter
17M-91 I-3530
195-211-6691
Element
Filter
2
1
195-71-61550
198-72-11181
(198-71-21710)
(198-71-I 1230)
(195-71-61950)
195-71-61930
195-71-61940
(198-71-21720)
(198-71-11230)
(195-71-61950)
Cutting edge
Cutting edge
(Bolt)
(Washer)
(Nut)
End bit (left)
End bit (right)
(Bolt)
(Washer)
(Nut)
198-72-11181
198-71-11181
(198-71-21710)
(198-71-I 1230)
(195-71-61950)
195-71-61930
195-71-61940
(198-71-21720)
(198-71-I 1230)
(195-71-61950)
Cutting edge
Cutting edge
(Bolt)
(Washer)
Semi
U-dozer
U-dozer
3-8
(Nut)
End bit (left)
End bit (right)
(Bolt)
(Washer)
(Nut)
Replacement
frequency
Every 250 hours
service
1
-
(I)
1
93.2
99.6
113.0
113.0
99.6
125.2
113.0
113.0
-
2
2
(22)
(22)
(22)
1
1
(16)
(16)
(16)
2
2
(26)
(26)
(26)
1
1
(16)
(16)
(16)
Every 500 hours

sevice
Every 1000 hours

service
Every 2000 hours

sevice
19. WEAR PARTS LIST
Item
Part No.
Multi
Replacement
frequency
Part Name
195-78-7 1111
195-78-71320
(195-78-71360)
Protector
Point
(Pin)
195-78-7 1111
195-78-7 1320
(195-78-71360)
Protector
Point
(Pin)
3
3
26.0
-
(9)
26.0
1
1
Ripper
Giant
NOTICE
When handling parts that weight
and take the necessary care.
more than 25 kg (55 lb), remember
(3)
that they are heavy objects,
3-9
20. USE OF FUEL COOLANT AND LUBRICAF

ACCORDING t0 AMBIENT TEMPERATUF
PROPER SELECTION OF FUEL, COOLANT
RESERVOIR
KIND OF
FLUID
AMBIENT
-4
-20
14
-10
32
0
AND LUBRICANTS
TEMPERATURE
50
10
68
20
86
30
Engine oil pan
Power train oil pan

(incl. transmission,
torque converter
and bevel gear
cases)
Hydraulic system
Cooling system
104Ol
40C
CAPACITY
Specified
amount
Refill
caDacitv
58 Q
15.31 US gal
12.76 UK gal
51 Q
13.46 US gal
11.22 UK gal
250 Q
66 US gal
55 UK gal
150 e
39.6 US gal
33 UK gal
2.1 Q
0.55 US gal
0.46 UK gal
2.1 Q
0.55 US gal
0.46 UK gal
270 Q
71.28 US gal
59.4 UK gal
120 Q
31.68 US gal
26.4 UK gal
65 Q
17.16 US gal
14.3 UK gal
65 Q
17.16 US gal
14.3 UK gal
Diesel fuel
1050 e
277.2 US gal
231 UK gal
Water
165 Q
43.56 US gal
36.3 UK gal
% ASTM D975 No. 1
3-10
Engine oil
Damper case
Fuel tank
ES
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
REMARK
l
When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur
Above
Change interval of oil in

engine oil pan
content
0.5 to 1.0%
1.0%
l/2 of regular
interval
l/4 of regular
interval
When starting the engine in an atmospheric

oil of SAEIOW, SAEIOW-30
and SAE15W-40,
IOC more or less in the day time.
Use API classification

interval to half.
There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30,
sure to add single grade oil that matches the temperature
in the table.
We recommend
Komatsu genuine oil which has been specifically
in engine and hydraulic work equipment
applications.
CD as engine
temperature
of lower than O-C, be sure to use engine
even though an atmospheric temperature
goes up to
oil and if API classification
Specified capacity: Total amount of oil including oil for components

Refill capacity: Amount of oil needed to refill system during normal
ASTM:
SAE:
API:
maintenance
CC, reduce the engine
formulated
oil change
15W-401,
and approved
but be
for use
and oil in piping.

inspection and maintenance.
American Society of Testing and Material

Society of Automotive
Engineers
American Petroleum Institute
3-11
20. USE OF FUEL, COOLANT
AND
Engine
LUBRICANTS
ACCORDING
TO AMBIENT
TEMPERATURE
Oil
[CD or CEI
ti0.
Supplier
SAEIOW,
30, 40
1ow30, 15w40
(The 15W40 oil
marked * is CE.)
Gear Oil
Grease
[Lithium-Base]
[GL-4 or GL-51
SAE80, 90, 140
NLGI No. 2
EOIO-CD
1
KOMATSU
AGIP
[Ethylene Glycol
Base]
Permanent
Type
AF-ACL
EOSO-CD
EOIO-30CD
E015-40CD
Diesel sigma S
Super dieselmultigrade
*Sigma
turbo
300
GO90
GO140
G2-LI
GS-LI-S
Rotra MP
GR MU/EP
Multi-purpose
AMOCO
*Amoco
ARC0
*Arcofleet
BP
Vanellus
CALTEX
*RPM delo 400

RPM delo 450
CASTROL
*Turbomax
*RX super
CRD
CHEVRON
*Del0 400
CONOCO
*Fleet motor oil
IO
ELF
Multiperformance
Performance 3C
EXXON
(ESSO)
Essolube D3
*Essolube XD-3
*Essolube XD-3 Extra
*ESSO heavy duty
Exxon heavy duty
12
GULF
13
MOBIL
3-12
Anti-freeze
Coolant
S3 plus
C3
gear
oil
AF-PTL
AF-PT (Winter, one
season typr
RYKON prenium
grease
Arco HD gear oil
Litholine HEP 2
Arco EP moly D
Gear oil EP
Hypogear EP
Energrease
Universal
Universal
thuban
thuban
LS-EP2
Marfak all purpose 2

EP Ultra-duty grease 2
EP
EPX
MS3
Spheerol
HYP~Y
HYP~Y B
HYP~Y C
EPL2
Antifreeze
AF engine coolant
Anti-freeze
Universal
gear
Ultra-duty
grease 2
Universal
gear
lubricant
Super-sta
grease
3C
Tranself EP
Tranself EP type 2
Glacelf
Gear oil GP
Gear oil GX
Beacon EP2
All season coolant
Super duty motor oil

*Super duty plus
Multi-purpose
gear
lubricant
Gulfcrown
Gulfcrown
Antifreeze
Delvac 1300
*Delvac super
1ow-30, 15w-40
Mobilube
Mobilube
Mobilux EP2
Mobilgrease 77
Mobilgrease special
GX
HD
EP2
EP special
and
coolani
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
No.
Supplier
Engine Oil
[CD or CEI
SAElOW, 30, 40
1ow30, 15w40
(The 15W40 oil
marked * is CE.)
Anti-freeze
Coolant
[Ethylene Glycol
Base1
Permanent Type
Gear Oil
[GL-4 or GL-51
SAE80, 90, 140
Grease
[Lithium-Base]
NLGI No. 2
Multi-purpose 4092
Multi-purpose 4140
Multi-purpose white
grease 705
707L White - bearing
grease
Anti-freeze and
summer coolant
FINA tamidor
14
PENNZOIL
*Supreme duty
fleet motor oil
15
PETROFINA
FINA kappa TD
FINA potonic N
FINA potonic NE
FINA marson EPLP
16
SHELL
Rimula X
Spirax EP
Spirax heavy duty
Alvania EP grease
17
SUN
Sunoco GL5
gear oil
Sunoco ultra prestige

2EP
Sun prestige 742
Sunoco antifreeze
and summer
coolant
18
TEXACO
*Ursa super plus

Ursa premium
Multigear
Multifak EP2
Starplex 2
Code 2055 startex

antifreeze coolant
19
TOTAL
Rubia S
*Rubia X
Total EP
Total transmission
TM
Multis EP2
Antigel/antifreeze
20
UNION
*Guardol
MP gear lube LS
Unoba EP
21
VEEDOL
*Turbostar
*Diesel star
MDC
Multigear
Multigear B
Multigear C
Antifreeze
3-13
21. ;&+lDARD
21.1
INTRODUCTION
The following
No.
TIGHTENING
OF NECESSARY
tools are needed
Name of tool
Wrench set
TORQUES FOR BOLTS AND
when
carrying
TOOLS
out maintenance.
Part No.
09000-30006
Remarks
Applicable width across flats (S, - S,)
8 mm - 10 mm, 12 mm - 14 mm
13 mm - 17 mm, 19 mm - 22 mm
s2
24 mm - 27 mm, 30 mm - 32 mm
Screwdriver
09033-00190
Interchangeable flat-head and cross-head type
Socket wrench set
09020-10284
Applicable width across flats
AC453370
10 mm, 13 mm
14 mm, 17 mm
19 mm, 22 mm, 24 mm, 27 mm, 30 mm, 32 mm, 36 mm
Extension, Handle, Joint
4
Wrench
09002-03641
36mm-41
mm
Wrench
0900 I-04600
Applicable wide across flats 46 mm
Plier
09036-00 150
Hammer
09039-00150
09055-10390
8
9
Filter wrench
0901 g-08035
For filter cartridges
10
Grease pump
07952-80002
For greasing work
11
Nozzle
07951-11400
For grease pump
12
Grease cartridge
07950-90403
(Lithium base grease, 400 g)
13
Gauge
09054-00009
If any of the above tools are broken, please order them from your Komatsu distributor.
When not using the tools, always put them in the tool box on the inside of the fender cover on the
right side of the machine.
3-14
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
21.2
TORQUE
LIST
Unless otherwise specified, tighten the metric bolts and nuts to

the torque shown in the table.
The tightening torque is determined by the width across the fiats
0J of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu
genuine part of the same size as the part that was replaced.
Nm (newton meter): 1Nm \ 0.1 kgm
Thread diameter
of bolt (mm)
Width across
flat (mm)
(a)
(b)
6
8
10
10
13.2 + 1.4
1.35 k 0.15
,9.73 k 1.03
13
31.4 f 2.9
3.2 + 0.3
23.2 zi2.1
17
65.7 2 6.8
6.7 2 0.7
48.5 + 5.0
12
19
112 + 9.8
11.5 -c 1.0
82.6 2 7.2
14
22
177 + 19
18.0 = 2.0
131 2 14
16
24
279 2 29
28.5 + 3
206 2 21
18
27
383 * 39
39 * 3
282 + 29
20
30
549 f 58
56 sz6
405 2 43
22
32
745 k 78
76 + 8
549 2 58
24
36
927 k 98
94.5 + 10
684 + 72
k
I--
Nm
AM)54300
km
Ibft
27
41
1320 r 140
135 A 15
973 f 100
30
46
1720 r 190
175 k 20
1270 2 140
33
50
2210 k 240
225 + 25
1630 2 180
36
55
2750 * 290
280 2 30
2030 + 210
39
60
3280 * 340
335 f 35
2420 + 250
NOTICE
When tightening
panels or other parts having tightening
fixtures made of plastic, be careful not to use excessive tightening
torque: doing so will damage the plastic parts.
3-15
22. PERIODIC REPLACEMENT
OF SAFETY CRITICAL PARTS
To ensure safety at all times when operating or driving the machine, the user of the machine must
always carry out periodic maintenance.
In addition, to further improve safety, the user should also carry
out periodic replacement
of the parts given in the table. These parts are particularly closely connected
to safety and fire prevention.
With these parts, the material changes as time passed, or they easily wear or deteriorate. However,
it is difficult to judge the condition of the parts simply by periodic maintenance,
so they should always
be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that
they always 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 as the hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same
time.
Ask your Komatsu distributor to replace the critical parts.
3-16
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS

No.
Safety critical parts for periodic
1 1 Fuel hose (between

2
1 Turbocharger
replacement
nozzles)
lubricating
Replacement
QW
interval
hose
Fuel hose (nozzle - fuel return hose)
Fuel hose for APS
Fuel hose (fuel filter - injection
pump)
Fuel hose (feed pump - fuel return hose)
Hose (blade valve - blade cylinder)

9
Inspection
hose assembly
10
Fuel hose (fuel tank - fuel strainer)
Hose (torque
converter
Fuel hose (fuel strainer
for power
train pressure
outlet - torque
converter
- feed pump)
14
Hose (ripper
low valve - ripper high valve)
15
Hose (ripper
high valve - work equipment
16
Hose (ripper
high valve - tank)
17
Hose (ripper
high valve - ripper
Hose (ripper
high valve - ripper tilt cylinder)
Hose (PPC charge
I
pump)
1
1
lift cylinder)
valve - PPC lock valve)
Hose (PPC lock valve - PPC valve for blade)

21
Hose (PPC lock valve - PPC valve for ripper)
22
Hose (PPC pump - PPC charge valve)

Hose (hydraulic
oil cooler - relay block)
Hose (relay block - PPC charge
valve)
Hose (relay block - suction tube)

26
Hose (PPC valve for blade - main valve)
3-17
22.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
No.
27
Safety critical
parts for periodic
replacement
Replacement
Qty
Hose (PPC valve for blade - PPC drain relay block)
interval
Hose (PPC valve for ripper - main valve)
Hose (PPC charge
valve - PPC drain relay block)
31
Hose (PPC drain relay block - suction tube)
32
Hose (work equipment
pump - blade lift valve)
33
Hose (work equipment
pump - ripper low valve)
34
Hose (blade valve - blade lift divider
35
Hose (blade
36
Hose (relay tube - blade lift cylinder)
37
Hose (ripper
38
Seat belt
lift divider
block)
block - relay tube)
low valve - blade tilt relay tube)
I
Every 2 years or 4000 hours,
whichever comes sooner
Every 3 years
AE210090
3-18
AL116130
3-19
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
AE206970
3-20
23. MAINTENANCE
23.1
MAINTENANCE
SCHEDULE CHART
SCHEDULE
CHART
SERVICE ITEM
INITIAL 250 HOURS SERVICE (only after the first 250 hours)
Replace
fuel filter cartridge
Replace
transmission
3-65
filter element
and torque
Change oil in power train case, clean strainer

converter case and bevel gear case)
Change
oil in hydraulic
Change
oil in final drive case
Check engine
tank, replace
converter
oil filter element
(incl. transmission
hydraulic
case, torque
3-66
3-69
3-73
oil filter element
3-74
valve clearance,
3-77
adjust
WHEN REQUIRED
Clean inside of cooling
3-26
system
Check, clean and replace
air cleaner
3-30
element
3-32
Check track tension

Check and tighten
Check electrical
Adjust
Reverse
3-34
track shoe bolts
3-34
intake air heater
3-35
idler clearance
and replace the end bits and cutting
Check and clean radiator
3-36
edges
3-38
fin
3-38
Clean fuel tank strainer

Drain water
Replace
and sediment
air conditioner
Clean, check hydraulic
3-38
in fuel tank
3-39
belt
3-39
cooler fins
3-40
Check undercarriage
oil
Clean air conditioner
air filter (fresh/recirc
Check, adjust air conditioner

Grease
(machines
door hinge (machines
equipped
Check door lock striker (machines

Replace
door damper
(machines
filter)
equipped
equipped
equipped
with cab)
3-42
3-42
3-43
with cab)
fluid level, add fluid (machines
Bleed air from
head end of right pitch cylinder
Replace
blade (machines
(power
with cab)
3-41
3-42
with cab)
with cab)
washer
equipped
equipped
with cab)
Check window
wiper
(machines
equipped
tilt, power
with cab)
pitch dozer only)
3-43
3-43
3-44
3-21
23. MAINTENANCE SCHEDULE CHART
SERVICE ITEM
PAGE
(WHEN REQUIRED)
Check APS (Automatic
Priming
System)
3-45
Lubricating
3-46
Fuel control
Steering
Universal
lever shaft (4 places)
brake control
3-46
3-46
joint (2 places)
3-47
CHECK BEFORE STARTING

Check machine
Check coolant
monitor
3-46
level, add water
3-46
3-49
Check fuel level, add fuel

Check oil level in engine
Check damper
3-50
oil pan, add oil
Check oil level in power train case (incl. transmission

and bevel gear case), add oil
case, torque
case oil level, add oil
Check brake pedal tavel
converter
case
3-51
3-52
3-52
Check oil level in hydraulic
tank, add oil
3-53
Check dust indicator
3-54
Check electric wirings
3-54
Check that lamps
3-55
light up
3-55
Check horn sound

Check backup alarm
sound
Check seat belt for wear
3-56
or damage
3-56
EVERY 250 HOURS SERVICE

3-57
Lubricating
3-57
shaft (2 places)
3-57
Blade left cylinder
Blade lift cylinder
Blade arm ball joint (3 places)
Brace screw (2 places)
Ripper tilt cylinder
bottom
pin (2 places)
3-57
Ripper
bottom
pin (2 places)
3-57
Ripper tilt cylinder
rod end pin (2 places)
3-57
Ripper lift cylinder
rod end pin (2 places)
3-57
3-22
lift cylinder
support
yoke (4 places)
support
3-57
23.
MAINTENANCE SCHEDULE CHART
SERVICE ITEM
PAGE
(EVERY 250 HOURS SERVICE)

l
Ripper arm pin (front)
Ripper arm pin (rear) (2 places)
3-57
Equalizer
3-58
Suspension
Fan pulley
Change
(2
Places)
3-57
bar side shaft (2 places)

(Equalizer
bar center shaft) (I place)
3-58
(I place)
oil in engine
3-58
oil pan, replace
Check oil level in hydraulic

Check, adjust alternator
Check level of battery
engine
oil filter cartridge
3-59
tank, add oil
3-61
drive belt tension
3-62
electrolyte
3-63
Check brake performance
3-64

3-65
Replace fuel filter cartridge

Replace
transmission
filter element
and torque
converter
oil filter element
3-66
Check oil level in final drive case, add oil
3-67
Check fan belt, replace
3-68

Change oil in power train case, clean strainers
converter case and bevel gear case)
(incl. transmission
case, torque
3-69
Check, clean fuel strainer
3-70
Clean steering
3-71
clutch case breather
Check oil level in recoil spring and assist cylinder

Grease tension
corrosion
bolts
resistor cartridge
Check all tightening
3-71
3-71
pulley assembly
Check for loose ROPS mount

Replace
case, add oil
3-72
parts of turbocharger
3-72

Change
oil in hydraulic
Change
oil in final drive case
3-74
Change
oil in damper
3-75
Check pivot bearing

Clean engine
tank, replace
hydraulic
oil filter element
case, clean air hole and breather

oil level, add oil
breather
element
3-73
3-76
3-76
3-23
23. MAINTENANCE SCHEDULE CHART
SERVICE
ITEM
(EVERY 2000 HOURS
SERVICE)
Clean, check turbocharger
3-77
Check play of turbocharger

Check alternator,
Check engine
starting
rotor
3-77
motor
valve clearance,
3-77
adjust
3-77
EVERY 4000 HOURS

Check water
pump
Check vibration
Check fan pully and tension
3-24
SERVICE
3-78
damper
Check main frame,
PAGE
3-78
pulley
work equipment
3-78
(blade,
ripper)
3-79
24. SERVICE PROCEDURE
24.1
INITIAL 250 HOURS
Carry out the following

hours.
l
l
l
l
l
SERVICE
maintenance
only after the first 250
REPLACE FUEL FILTER CARTRIDGE

REPLACE TRANSMISSION
FILTER ELEMENT AND TORQUE
CONVERTER OIL FILTER ELEMENT
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINER (INCL.
TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL
GEAR CASE)
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL
FILTER ELEMENT
CHANGE OIL IN FINAL DRIVE CASE
CHECK ENGINE VALVE CLEARANCE, ADJUST
For details of the method of replacing or maintaining,

section on EVERY 500 HOURS, 1000 HOURS AND 2000
SERVICE.
see the
HOURS
3-25
24.2
WHEN
REQUIRED
24.2.1 CLEAN INSIDE OF COOLING
SYSTEM
WARNING
Soon after the engine has been stopped, the coolant is hot
and can cause personal injury. Allow the engine to cool
before draining water.
Never be under the machine with the engine running. To
avoid serious injury, always stop the engine before being
under the machine to open the drain valve.
Never remove the radiator cap when the engine is at operating temperature.
At operating
temperature,
the coolant is
under pressure. Steam blowing up from the radiator could
cause personal injury. Allow the engine to cool until the
radiator filler cap is cool enough to touch with your hand.
Remove the filler cap slowly to relieve pressure.
When removing drain plug, avoid pouring coolant on yourself.
Antifreeze is flammable,
so keep it away from any flame.
l
Clean the inside of the cooling system, change the coolant and
replace the corrosion resistor according to the table below.
Kind of coolant
Cleaning inside of
cooling system and
changing coolant
Permanent type antifreeze

(All season type)
Every year (autumn) or

every 2000 hours
whichever comes first
Non permanent
type
antifreeze containing
ethylene glycol (Winter,
one season type)
Every 6 months (spring,

autumn)
(Drain antifreeze in spring,
add antifreeze in autumn)
When
Every 6 months or every

1000 hours whichever
comes first
3-26
not using antifreeze
Replacing corrosion
resistor
Every
when
of the
when
1000 hours and

cleaning the inside
cooling system and
changing coolant
Use a permanent type of antifreeze.

If, for some reason, it is impossible
to use permanent
antifreeze, use an antifreeze containing ethylene glycol.
Stop the machine
the coolant.
on level ground
when
cleaning
type
or changing
When deciding the ratio of antifreeze to water, check the lowest

temperature
in the past, and decide from the mixing rate table
given below.
It is actually better to estimate a temperature
about 10C (50F)
lower when deciding the mixing rate.
Mixing
rate of water
and antifreeze
We recommend use of an antifreeze

mixing proportions.
density gauge to control the
Use city water for the cooling water.

If river water, well water or other such water
used, contact your Komatsu distributor.
supply
must be
3-27
24. SERVICE
PROCEDURE
1.
Stop the engine
2.
Turn radiator
3.
Set a container to catch the coolant, open drain valve @ at the

bottom of the radiator and drain valve @ at the bottom of oil
cooler and drain plugs @ at the both sides of cylinder block, and
drain off the cooling water.
and tighten
cap @ slowly
valve @ of the corrosion

and remove
resistor.
it.
4.
After draining, close up drain valve 0, @ and plugs @ and pour

in clean water (ex. city water) up to the vicinity of the water filler.
5.
When the water reaches the vicinity of the water filler, put the
engine at low idling, open drain valve 0, @ and plugs 0, then
pass water through the cooling system for 10 minutes.
When doing this, keep the radiator filled up to the filler with
water.
When filling with water, be careful to check that the hose
supplying the water does not come out of the water filler port
at the radiator cap.
After washing the cooling system, stop the engine.

and close drain valve 0, @ and plugs 0.
7.
After draining the water, flush the system with a flushing agent.
For details of the flushing method, see the instructions on the
flushing agent.
8.
After flushing,
open drain valve 0, @ and drain plugs 0,
completely
drain all the water, then close the drain valve and
drain plug, and fill with city water up to near the filler port.
9.
When the tank is filled to near the water filler port, open drain
valve 0, @ and drain plugs 0, start the engine, run at low idling,
and continue the flushing operation until clean water comes out.
Drain water
While flushing the radiator, adjust the incoming flow of water to

match the drain flow so that the radiator is always kept full during
the flushing operation. Be sure that the water supply hose does not
slip out of the radiator water filler when flushing.
10. When clean water comes out, stop the engine
valve 0, @I and drain plug 0.
and close drain
11. Replace the corrosion resistor and open valve 0.

For details on the corrosion resistor replacement
24.6 EVERY 1000 HOURS SERVICE.
12. Add city water
port.
until the water
overflows
from
method,
the water
see
filler
13. To remove the air in the cooling water, run for five minutes
low idling, then for another five minutes at high idling.
(When doing this, leave the radiator cap off.)
3-28
at
AE20898C
14. Stop the engine, wait for 3 minutes, add city water until the water
level reaches near the water filler port, then tighten the cap 0.
15. Open the cap of subtank @ and add water into the subtank
referring to the section 24.3 CHECK BEFORE STARTING.
3-29
24.2.2 CHECK, CLEAN AND REPLACE AIR CLEANER

ELEMENT
Never clean or replace the air cleaner element with the engine
When using pressure air to clean the element wear safety
glasses or goggles to protect the eyes.
CHECK
If the red piston can be seen in transparent
indicator 0, clean the air cleaner element.
portion of dust
CLEAN, REPLACE OUTER ELEMENT

1. Loosen wing nut 0, then remove the outer element 0.
2.
Clean the air cleaner body interior.
3.
Direct dry compressed air (less then 700 kPa (7 kg/cm*, 100 psi))
to the element from inside along its folds, then direct it from
outside along its folds and again from inside.
I) Remove one seal from the outer element. The number of
times the outer element has been cleaned can be seen by the
number of removed seals.
2) Replace the outer element which has been cleaned 6 times
repeatedly or used throughout a year. Replace the inner
element at the same time.
3) Replace the element when the air cleaner clogged warning
lamp lights up soon after installing the cleaned element even
though it has not been cleaned 6 times.
4) Check inner element mounting nuts for looseness and, if
necessary, retighten.
5) Replace seal washer @I or wing nut @with new parts if they
are broken.
NOTICE
If small holes or thinner parts are found on the element when
it is checked with an electric bulb after cleaning and drying, replace
the element.
Do not use an element whose folds or gasket or seal are
damaged.
When cleaning the element, do not hit it or beat it against
something.
AE083070
AE083060
AE083080
4.
Set the cleaned element.
3-30
REPLACING INNER ELEMENT

1. First remove
element.
the
outer
element,
and then
remove
the
inner
2.
To prevent dust from getting in, use a clean cloth or tape to cover
the air connector (outlet side).
3.
Clean the air cleaner

installed in Step 2.
4.
Fit a new inner element to the connector and tighten

Do not clean and reinstall a inner element.
5.
Install the outer element.
6.
After replacing the element, press button of the dust indicator to

return the red piston to its original position.
body
interior,
then
remove
the
cover
it with nuts.
3-31
24. SERVICE
PROCEDURE
24.2.3 CHECK TRACK TENSION

The wear of pins and bushings on the undercarriage
will vary
with the working conditions and soil properties. 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).
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 is 20 - 30 mm (0.8 - 1.2 in),
the tension is standard.
If the track tension is not at the standard value, adjust it in the
following
manner.
ADJUSTMENT
WARNING
Grease inside the adjusting mechanism is under high pressure.

Grease coming from plug @ under pressure can penetrate the
body causing injury or death. For this reason, do not loosen plug
@I more than one turn. Do not loosen any part other than plug
0. Furthermore,
do not bring your face in front of the grease
fitting.
If the track tension is not relieved by this procedure,
please
contact your Komatsu distributor.
1.
When increasing tension

First remove the bolt 0,
and then remove
the cover 0.
NOTICE
When
removing
Pump
in grease
cover 0,
be careful
through
the grease
not to let soil get in.

fitting
@ with
a grease
pump.
To check that the correct tension has been achieved,
machine backwards and forwards.
Check the track tension
adjust it again.
again, and if the tension
move the
is not correct,
Continue to pump in grease until S becomes 560 mm (22.1 in).

If the tension is still loose, the pin and bushing are excessively
worn, so they must be either turned or replaced. Please contact
your Komatsu distributor.
3-32
When
loosening
It is extremely
relieved
tension
dangerous
to release the grease by any method
by this procedure,
please
contact
your
Komatsu
1.
Loosen
2.
Turn plug @ a maximum
3.
If the grease does not come out smoothly,

backwards and forwards a short distance.
4.
Tighten
5.
To check that the correct tension has been achieved,

machine backwards and forwards.
6.
Check the track tension

adjust it again.
When
plug @ gradually
dis-
to release the grease.

of one turn.
move the machine
plug 0.
removing
again,
and if the tension
move the
is not correct,
track
WARNING
Depending on the situation, the operation to remove the track

may be extremely
dangerous.
Before removing the track, if the procedure above When loosening tension does not loosen the track tension, please contact
your Komatsu distributor for repair.
3-33
24.2.4 CHECK AND TIGHTEN
TRACK SHOE BOLTS
If the machine is used with track shoe bolts loose, they will break,
so tighten any loose bolts immediately.
Method for tightening
(shoe bolt)
First tighten to a tightening torque of 686 + 69 Nm (70 f 7 kgm,
506 f 51 Ibft)) then check that the nut and shoe are in close
contact with the link contact surface.
1.
2.
After checking,
tighten
e
1.
Method for tightening

(master link connecting bolt)
First tighten to a tightening torque of 490 +. 49 Nm (50 f 5 kgm,
362 f 36 lbft) then check that the link contact surfaces are in close
contact.
2.
After checking,
tighten
a further
a further
120 + 10.
180 2 10.
Order for tightening

Tighten the bolts in the order shown in the diagram
on the right.
/
I
24.2.5 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.
3-34
AD053090
24.2.6 ADJUST
IDLER CLEARANCE
The idler moves forward and backward under external pressure.

When this happens, side guide 0 and guide plate @ become worn.
As they become worn, there is side play in the idler, or the idler turns
at an angle, causing the track to come off or resulting in uneven
wear, so adjust as follows.
Adjustment
1. Drive the machine for 1 - 2 m (3 - 7 ft) on flat ground, then
measure clearance A (4 places: left, right, inside, outside) between
the track frame and side guide 0.
2.
If clearance A is more than 3 mm (0.1 in), remove bolt 0, then

take out shim 0, and adjust so that the clearance on one side is
less than 0.5 mm (0.02 in).
REMARK
There are two types of shim (thickness:
mm (0.04 in).
0.5 mm (0.02 in) and 1.0
t.J
AL116270
3-35
24.2.7
REVERSE
CUlTlNG
AND REPLACE THE END BITS AND

EDGES
&h WARNING
It is dangerous if the work equipment

moves by mistake when
the cutting edges and end bits are being reversed or replaced.
Set the work equipment
in a stable condition, then stop the
engine and lock the blade control lever securely with the safety
lever.
Reverse or replace the end bits and cutting edges before it is
worn out to the blade end.
1. Raise the blade to a proper height and apply a block to the frame
so as to prevent fall of the blade.
2.
Operate
the safety lever to the LOCK position.
If the cutting edge and the end bit on both sides are worn
replace with new one.
If it has been worn out up to the fitting surface,
surface and then reverse or replace.
out,
repair the fitting
3.
Loosen nut @ and remove bolt 0. Then remove the cutting edge
and the end bit and clean the mounting surface.
4.
Reverse or replace the cutting edge and the end bit when worn
out.
If bolt @) and nut @ are damaged,

at the same time.
5.
Install the edge to the blade, then tighten partially. Drop the
blade three to five times on to the ground or rock to remove any
play in bolt 0, then tighten it to the correct tightening torque.
When installing end bit 0, put top surface @ of the end bit in
close contact with stopper 0, then tighten with the bolts.
Tightening
3-36
replace them with new ones
torque: 2226 f 275 Nm (227 & 28 kgm, 1642 + 203 Ibft)
6.
After several
hours of running,
retighten
the nuts.
REMARK
The tightening operation
been supplied is used.
When the nut is

both sides @ of the
Be careful not to
If it is damaged,
mounting surface.
is easier if the power wrench
rusted and is removed by gas cutting,

nut as shown in the diagram.
damage seat surface 0.
repair it. Be careful not to get spatter
that has
cut on
a
on the
7
/
=.455
AE200610
3-37
24.2.8 CHECK AND CLEAN RADIATOR

g
FIN
WARNING
When carrying out cleaning or inspection,

always
engine and check that the fan is not rotating before
When the radiator
follows.
bolts 0
stop the
starting.
fin block with mud, dirt or leaves, clean it as
1.
Loosen
and open radiator
grille 0.
2.
Clean the radiator fins clogged with mud, dust and leaves with
compressed
air. Steam
or water
may be used instead of
compressed
air.
REMARK
Check the rubber hose. If the hose is found to have cracks to be
hardened
by ageing, replace such hose with new one. Further,
loosen hose clamp should also be checked.
24.2.9 CLEAN FUEL TANK STRAINER

Clean the strainer if there is any dirt collected in it.
Remove the filler cap of the fuel tank and take out strainer
If the strainer is dirty, clean it with diesel fuel.
0.
24.2.10
DRAIN
WATER
AND SEDIMENT
IN FUEL TANK
Carry out this procedure after the machine has been at rest for
a long time and after a long spell of rainy days.
Loosen valve 0 at the bottom of the tank and drain sediment
accumulated
on the bottom together with mixed water and fuel.
3-38
24.2.11
REPLACE AIR CONDITIONER
1.
Loosen 4 bolts @ and jack bolt 0,

the side.
2.
Replace
BELT
then move compressor
@ to
the V-belt.
REMARK
When adjusting the V-belt,
with a bar. Use jack bolt 0.
3.
do not push the compressor
directly
Tighten jack bolt @ and bolts 0, and apply tension to the V-belt.
The standard deflection for the V-belt is approx. 15 - 18 mm (0.6
- 0.7 in) when the belt is pushed by thumb (approx. 10 kg (22 lb))
at a point midway between the air compressor
pulley and fan
pulley.
24.2.12
CLEAN, CHECK HYDRAULIC
If the hydraulic cooler fins are clogged

the fins, clean and check the fins.
COOLER FINS
or there is dirt caught
in
1.
Open the inspection
cover on the left.
2.
Use compressed
air to remove the mud, dirt, and leaves clogging the hydraulic cooler fins. Steam or water may be used
instead of compressed
air.
REMARK
Inspect the rubber hoses, and replace them
or brittle. Check also for loose hose clamps.
if they are cracked
3-39
24.2.13
CHECK UNDERCARRIAGE
OIL
Stop the machine on level ground, and check for any reduction
in the oil at the idler (portion P), track roller (portion Q), bogie shaft
(portion Q), and carrier roller (portion R).
1.
Loosen seal bolt @ slowly and check if oil oozes out from the
thread. If oil oozes out, the oil level has not gone down, so
tighten the bolt.
2.
If no oil comes out even when seal bolt @ is removed, the oil
level is low, so please contact your Komatsu distributor for
repair.
REMARK
There
outside.
is one bogie
shaft seal bolt @ each on the inside
and
IL---+-
3-40
AD053230
24.2.14
CLEAN AIR CONDITIONER AIR FILTER

(FRESH/RECIRC FILTER)
If the air conditioner

in it, clean the filter.
inspection
air filter is clogged
1.
Open
2.
Open inspection cover @ under the front

recirculation
air filter @ to remove it.
3.
Clean filters @ and @ with compressed

air. If there is oil stuck
to the filter, or it is extremely dirty, wash it in a neutral agent.
After washing it, dry it completely
before installing it again.
REMARK
If the clogging
using compressed
cover @ and remove
or there is dirt or dust
fresh air filter 0.

panel
and pull up
of the filter cannot be removed by washing

air, replace the filter with a new part.
or
3-41
24.2.15
CHECK, ADJUST AIR CONDITIONER

comDressor
CHECKING TENSION OF COMPRESSOR

BELT
If the belt is loose, it will slip and the cooling effect will be
reduced. From time to time, press a point midway between the drive
pulley and compressor pulley with your finger (approx. 10 kg (22 lb))
and check that the tension is 15 - 18 mm (0.6 - 0.7 in).
When the belt is new, there will be initial elongation, so always
adjust again after 2 or 3 days.
CHECK LEVEL OF REFRIGERANT
The refrigerant
Drive
pulley
Dulley
AE20915E
(GAS)
used in the cooler is colorless
and odorless
and
eyes or on your hands, it may cause loss of sight or frostbite,

so never loosen any part of the refrigerant circuit.
If the level of the refrigerant (gas) is low, the cooling effect will
be reduced. Run the engine at high idling, and check the flow of the
refrigerant in the refrigerant circuit through the sight glass of the
receiver when the cooler is running at high speed.
l
No bubbles in refrigerant flow: Correct
l
Bubbles in refrigerant flow (bubbles continuously pass through):
Refrigerant level low
l
Colorless, transparent:
No refrigerant
REMARK
When there are bubbles, the refrigerant
gas level is low, so
contact your refrigerant dealer to have refrigerant added. If the air
conditioner
is run with the refrigerant gas level low, it will cause
damage to the compressor.
New Freon R-134a is used as refrigerant.
AC053280
24.2.16
GREASE DOOR HINGE

If the door makes a squeaking noise when it is opened or closed,

spray lubricant in through the split in the hinge bushing.
If the bushing is worn, replace the hinge.
24.2.17
CHECK DOOR LOCK STRIKER

If the wear of the doors lock striker exceeds 0.5 mm (0.02 in),
replace the striker. If it is used at it is, the play will increase and this
may result in breakage of the hinge or door lock.
3-42
24.2.18
If the
(0.08 in),
There
and right
24.2.19
REPLACE DOOR DAMPER

depth of the door damper rubber groove is less than 2 mm
replace the damper.
are two dampers each at the top and bottom on the left
doors.
CHECK WINDOW WASHER FLUID LEVEL, ADD

FLUID (MACHINES EQUIPPED WITH CAB)
If there is air in the window washer fluid, check the level and add
fluid.
Open the battery cover, check the level of the fluid in window
washer tank 0, and if it is low, add automobile window washer fluid.
When adding fluid, be careful not to let dirt or dust get in.
24.2.20
BLEED AIR FROM HEAD END OF RIGHT PITCH

CYLINDER
(POWER TILT, POWER PITCH DOZER ONLY)
Bleed the air if the work equipment

has been removed
or
repaired.
1. Raise the blade and run the engine at low idling.
2. Operate the left and right tilt 5 - 10 times to bleed the air from
the tilt circuit.
3. Operate the forward and rear pitch 5 - IO times to bleed the air
from the bottom end of the right cylinder.
4. Set the left and right cylinders at the neutral position, then carry
out the following operations 5 - 10 times to bleed the air from
the head end of the right pitch cylinder.
@ Forward pitch
1
@ Left tilt
L
@ RigFt tilt
@I Rear pitch i
3-43
24. SERVICE
24.2.21
PROCEDURE
REPLACE WIPER BLADE

If the blade is damaged,

replace the blade.
it will not wipe the window
Method of replacement
l
Front, rear wiper
1. Remove screw 0, then remove
2.
Install a new blade, then tighten
clean,
so
the blade.
screw @I securely.
AD053340
I
1.
Door wiper
It is hooked at portion @, so move the blade in the direction
the arrow to remove it.
2.
Install the new blade and hook it securely.
Rear wiper
AW53350
of
AD053360
3-44
24.2.22
CHECK APS (Automatic
Priming System)
Check the APS in autumn (ambient temperature

below 15C,
engine cooling water temperature
below 13C).
If it is necessary to inspect the APS when the engine cooling
water is above 13C, so please contact your Komatsu distributor.
1. Open fuel valve @ of the APS and remove
inlet.
hoses @ of the nozzle
2.
Move feed pump @ up and down to bleed air until no air bubbles
comes out of the hose connecting port.
At the same time, check for fuel leakage and clogging of fuel
pipe.
3.
Place the fuel control lever in the engine stop position. Turn
the starting switch to ON position. Turn on the preheater switch.
Then, confirm the following.
l
Confirm that the preheater monitor lamp stays on for about
80 seconds.
l
Confirm that when the preheater monitor lamp goes off, the
two glow plugs are red hot.
l
With preheater monitor lamp off, turn the starting switch key
to START position (do not keep the key in this position for
more than 20 seconds), and checkfor properfuel combustion
inside the intake manifold.
When
checking
the glow
If any abnormality
SHOOTING.
plug, remove
is assumed,
refer
plug.
to the
16.
TROUBLE
3-45
24. SERVICE
24.2.23
PROCEDURE
LUBRICATING
1.
2.
Using a grease pump, pump

fittings shown by arrows.
3.
After greasing,
1.
Fuel control
2.
Steering
3-46
wipe
to the ground,
in grease
then stop the engine.

through
off any old grease that was pushed
brake control
the
grease
out.
3.
Universal joint
Apply grease to the grease fittings
(2 places) shown
by arrows.
The undercoy
is heavy?
wARNNG-pi
Never try to open or close the cover when directly beneath it
When removmg bolts 0, carry out the work from the rear below
the cover so that you can easily get out of the way.
Remove inspection cover @ of the undercover

of the chassis as follows.
AE209210
at the rear bottom
(I) Remove 2 bolts @ at the front of the machine.

(2) Support the cover with your elbow while gradually
bolts @ at the rear of the machine.
(3) Lower the cover gradually to open it.
removing
Fr
m
AD054002
3-47
24. SERVICE
PROCEDURE
24.3 CHECK BEFORE STARTING
Machines
eWiPDed
24.3.1 CHECK MACHINE MONITOR

1. Turn starting switch @ to the ON position.
2.
with
Cab
E-I-3
Check that all monitor lamps and gauges light up for 3 seconds
and the alarm buzzer sounds for about 2 seconds.
REMARK
If the lamps do not light up, there may be a failure or disconnection
in the monitor, so please contact your Komatsu distributor.
Machines
yzz-y
eauimed
AE203338
with
CanODY
NOTICE
When carrying out the checks before starting, do not relay only
on the monitor.
Always
carry out all the items listed for the
following
check and maintenance.
OFF
24.3.2 CHECK COOLANT
Do not remove
cap 0,
LEVEL, ADD WATER
@ while
cooling water
by little
by
Remove radiator cap @ and check that coolant is above the

bottom of the strainer as shown in the diagram. If necessary, add
water through filler of radiator cap 0.
2.
Check that threre
3.
If the water level is low, add water through fillers of both radiator
cap @ and subtank cap 0. Add into the subtank up to the level
above the bottom of strainer through filler of cap @ as shown
in the diagram.
is no abnormality,
To refill the radiator, first stop the engine and pour in water until
the water overflows the filler opening. Then, start the engine,
check the water level again after a five-minute
idling, and add
water if necessary.
5.
After adding
6.
If the volume of coolant

possible water leakage.
3-48
tighten
the cap 0,
added
I-
*E20,1
Racliatof
such as oil in the coolant.
4.
water,
AD052290
is hot. Hot water
goes down and release radiator

pressure little
loosening caps slowly, then remove the cap.
1.
START
AE20092E
Sulstank
@ securely.
is more
than
usual, check for
AE200939
24.3.3 CHECK FUEL LEVEL, ADD FUEL

a
When adding
a fire.
1.
2.
WARNING
fuel, never let the fuel overflow.
Turn the engine starting switch to the ON position and check the
fuel level with fuel level gauge 0 on the monitor panel.
After checking, turn the switch back to the OFF position.
After completing work, fill the

Check the fuel level with the
For details of the fuel to use,
AND LUBRICANTS
ACCORDING
3.
This may cause
fuel tank through fuel filler port 0.

fuel gauge at the fuel filler port.
see 20. USE OF FUEL, COOLANT
After adding fuel, tighten the cap securely.

Fuel capacity: 1050 & (277 US gal, 231 UK gal)
REMARK
o When dozing on a grade, make sure there is plenty of fuel in the
tank so that the engine fuel line does not becomes aerated.
l
If breather hole @ on the cap is clogged, the pressure in the tank
will drop and fuel will not flow.
Clean the hole from time to time.
AD054210
3-49
24. SERVICE
PROCEDURE
24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

1. Open the engine side cover on the right side of the chassis.
2.
Remove
dipstick @ and wipe the oil off with a cloth.
3.
Insert dipstick 0 fully in the oil filler pipe, then take it out again.
4.
be between
0.
oil filler
0.
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.
AL116000
5.
If the oil is above the H mark, remove drain plug 0, loosen drain
valve @ to drain the excess oil, then check the oil level again.
6.

close the engine side cover.
the oil filler cap securely
and
REMARK
l
l
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.
l
l
When adding oil, remove the dipstick from the holder to release
the air inside the crankcase.
3-50
AL116450
24.3.5 CHECK OIL LEVEL IN POWER TRAIN CASE (INCL.

TRANSMISSION,
TORQUE CONVERTER AND
BEVEL GEAR CASES), ADD OIL
Start the engine and run at idling for 5 minutes,
oil level with the COLD side of dipstick 0.
Remove
dipstick 0,
then check the
and wipe the oil off with a cloth.
Inset-t dipstick @ fully in the oil filler pipe, then take it out again.
be between
0.
If the oil level is belowthe
L mark, add engine oil through
oil filler
0.
AND
LUBRICANTS
ACCORDING
5.
If the oil is above the H mark, pull out hose 0, and loosen drain
plug @ to drain the excess oil, then check the oil level again.
6.
the oil filler cap securely.
REMARK
l
l
When the engine is stopped, the oil level will rise, so it is
impossible to check the oil level correctly. When checking while
the engine is running, run the engine at idling and check with the
HOT side of dipstick 0.
l
When working on a slop of more than 20, check that the oil is
up to the H level.
=W-
AE208408
3-51
24.3.6 CHECK DAMPER CASE OIL LEVEL, ADD OIL

1. Remove dipstick 0, and wipe the oil off with a cloth.
2.
Insert dipstick
again.
fully
3.
into the dipstick
be between
holder,
then pull it out
0.
If the oil is below the L mark, add engine oil through
holder.
AND
4.
the dipstick
LUBRICANTS
ACCORDING
If the oil is above the H mark, drain the excess oil from
plug. After draining the oil, check the oil level again.
drain
REMARKS
l
l

When checking the oil level, if the machine is at an angle, move
it to a horizontal position before carrying out the check.
24.3.7 CHECK BRAKE PEDAL TRAVEL

1.
Depress
2.
The distance of travel at the center of the pedal (position in the

diagram on the right) should be 65 - 85 mm (2.56 - 3.35 in).
3.
When this value exceeds the specified range, or the brake fails
to work, please contact your Komatsu distributor for adjustment.
3-52
the brake pedal all the way until it stops.
AD053630
24. SERVICE
24.3.8 CHECK OIL LEVEL IN HYDRAULIC
PROCEDURE
TANK, ADD OIL
When removing
the oil filler cap, oil may spurt out, so stop the
to go down, then turn
the cap slowly to release the internal pressure before removing
NOTICE
1. Lower the blade to the ground,
about 5 minutes before checking
H and L in sight gauge 0.
stop the engine and wait for

oil level. If oil level is between
Proper range
L
ADO53410
2.
If the level is below the L mark, add engine
oil through
oil filler
0.
REMARK
When
horizontal
inspecting,
if the machine is at an angle,
move
it to a
WARNING
If oil has been added to above the H mark, stop the engine and
wait for the hydraulic oil to cool down. Then remove drain plug
@, loosen drain valve 0, and drain the excess oil.
3-53
DUST
INDICATOR
24 .3.9 CHECK
1. Open the engine side cover on the right side of the chassis,
check that the red piston has not appeared in the transparent
portion of dust indicator 0.
2.
If the red piston has appeared,

clean
immediately.
For details of the method of cleaning
WHEN REQUIRED.
or replace
the element
the element,
see 24.2
After checking, cleaning, and replacing, press the knob of dust

indicator @I to return the red piston to its original position.
3.
AD052091
24.3.10
CHECK
ELECTRIC
a
WIRINGS
WARNING
If the fuse blows frequently, or there are traces of shortcircuiting

in the electric wiring, always locate and repair the cause.
Check for damage of the fuse and any sign of disconnection
or
short circuit in the electric wiring. Check also for loose terminals and
tighten any loose parts. Check the following points carefully.
l
Battery
0
Starting motor
l
Alternator
Please contact your Komatsu distributor for investigation
and
correction of the cause.
WARNING
Accumulation
of flammable
material (dead leaves, twigs, grass,
etc.) around the battery may cause fire, so always check and
remove such material.
When carrying walk-around
checks or checks before starting,
always check if there is any accumulation
of flammable
material
around the battery, and remove such flammable
material.
3-54
24.
24.3.11
1.
CHECK THAT LAMPS LIGHT UP
SERVICE
PROCEDURE
OFF
START
ADO52290
2.
Turn the front lamp and working lamp switch to the ON position
and check that the front lamps and working lamp light up.
AD051790
3.
Turn the rear lamp switch to the ON position and check that the
rear lamps on the left and right fenders light up.
If the lamps do not light up, there is probably a broken bulb or

disconnection
in the wiring, so contact your Komatsu distributor for
repairs.
24.3.12
CHECK HORN SOUND
OFF
ON
LJ
f
(3
AD051790
OFF
START
AD052290
2.
Press the horn switch
and check that the horn sounds.
3-55
24. SERVICE
24.3.13
1.
PROCEDURE
CHECK BACKUP ALARM SOUND
OFF
START
AD052290
2.
Set the joystick to the REVERSE position. The buzzer must sound
immediately.
The buzzer will continue to sound until the iovstick
is moved to the NEUTRAL or FORWARD position.
_ .
24.3.14
CHECK SEAT BELT FOR WEAR OR DAMAGE
Check the belt and mounting

damaged,
replace the seat belt.
3-56
clamps,
and if they are worn
or
24.4
EVERY 250 HOURS
SERVICE
24.4.1 LUBRICATING
1.
2.
Using a grease pump, pump

fittings shown by arrows.
3.
After greasing,
1.
2.
Blade lift cylinder

Blade lift cylinder
3.
4.
Blade arm ball joint (3 places)

Brace screw (2 places)
5.
6.
7.
8.
9.
10.
Ripper
Ripper
Ripper
Ripper
Ripper
Ripper
wipe
to the ground,
in grease
then stop the engine.

through
the
off any old grease that was pushed
support
support
grease
out.
yoke (4 places)
shaft (2 places)
tilt cylinder bottom pin (2 places)

lift cylinder bottom pin (2 places)
tilt cylinder rod end pin (2 places)
lift cylinder rod end pin (2 places)
arm pin (front) (2 places)
arm pin (rear) (2 places)
The ripper on the upper side is a multishank

on the lower side is a giant ripper.
ripper, and the one I
--'
AL116400
3-57
11. Equalizer bar side shaft (2 places)
12. Suspension (Equalizer bar center shaft) (1 place)

Grease the suspension through the grease fittings marked by
arrow.
Pump the greasing lever up and down 3 - 5 times.
13. Fan pulley (I place)
3-58
24.4.2 CHANGE OIL IN ENGINE OIL PAN,

REPLACE ENGINE OIL FILTER CARTRIDGE
The oil is at high temperature

after the engine has been operated
so never change the 011 immediately
after finishing operations.
Wait
for
the
oil
to
cool
down
before
1*
wARNNG/changing it.
Preoare the followina.

Container to catch drained oil: Min 51 L?capacity
0
Refill capacity: 51 e (13.46 US gal, 11.22 UK gal)
0
Socket wrench, filter wrench.
0
1.
Open cover on the under the chassis. Set a container

oil under the drain valve.
2.
Remove drain plug @ and loosen drain valve @ slowly to avoid

getting oil on yourself, and drain the oil.
Take care not to loosen drain valve @ so much that the stopper
pin in the valve is distorted.
Tightening torque drain valve 0: 69 i 10 Nm
(7 f 1 kgm, 51 2 7 Ibft)
Tightening torque drain valve 0: 64 + 15 Nm
(6.5 + 1.5 kgm, 47 + 11 Ibft)
3.
Check the drained oil, and if there are excessive metal particles
of foreign material, please contact your Komatsu distributor.
4.
Tighten
5.
Using a filter wrench, remove full-flow filter cartridge @ by

turning it counterclockwise.
When doing this, to prevent getting oil on yourself, do not carry
out this operation from immediately
under the cartridge.
In particular, if this operation is carried out immediately
after
stopping the engine, a large amount of oil will come out, so wait
for 10 minutes before starting the operation.
6.
Clean the filter holder, fill a new cartridge with clean engine oil
and coat the packing surface and thread of the new filter
cartridge with engine oil (a thin coat of grease is also possible),
then install the cartridge.
to catch the
drain valve 0.
3-59
24. SERVICE
PROCEDURE
7.
When installing the filter cartridge, bring the packing surface into
contact with the filter holder, then tighten a further 3/4 - 1 turn.
8.
After replacing the filter cartridge, add engine oil through oil
filler @ until the oil level is between the H and L marks on the
dipstick.
9.
Run the engine at idling 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 24.3 CHECK BEFORE STARTING.
NOTICE
Even if the machine has not been operated for 250 hours, the oil
and filter cartridge must be replaced when the machine has been
operated for 6 months.
In the same way, even if the machine has not been operated for
6 months, the oil and filter cartridge must be replaced when the
machine has been operated for 250 hours.
3-60
24.4.3 CHECK OIL LEVEL IN HYDRAULIC
TANK, ADD OIL
&k WARNING
l
When removing the oil filler cap, oil may spurt out, so stop
the engine and wait for the oil temperature
to go down, then
turn the cap slowly to release the internal pressure before
removing the cap.
If oil has been added to above the H mark, stop the engine
and wait for the hydraulic oil to cool down, then drain the
excess oil from the drain plug.
1.
Lower the blade to the ground in horizontal position, lower the

ripper shankvertically
and put the tip of the shank in contact with
the ground.
2.
Stop the engine and wait for about 5 minutes before checking oil
level. If oil level is between top and bottom of red circle sight
gauge 0, it is normal.
NOTICE
3.
If the level is below the L mark, add engine
oil through
oil filler
0.
AND
LUBRICANTS
ACCORDING
3-61
24.
SERVICE
PROCEDURE
24.4.4 CHECK, ADJUST

TENSION
ALTERNATOR
DRIVE BELT
CHECK
The standard deflection for the drive belt is approx. 15 mm (0.59
in) when pressed by thumb (approx. 6 kg (13.23 lb)) at a point
midway between the drive pulley and alternator pulley.
ADJUSTING
1. Loosen
bolts and nuts 0,
Alternator
@ and 0.
pulley
I
2.
3.
Turn nut @ clockwise, then move alternator @ to adjust the belt

tension so that the deflection is approx. 15 mm (0.59 in) when
pushed with a force of 6 kg.
Tighten the bolts and nuts 0,
position.
@ and @ to fix alternator
I
About 15mm
@ in
Drive pulley
A0053430
4.
Check each pulley for damage, wear of the V-groove, and wear
of the V-belt. In particular, be sure to check that the V-belt is not
touching the bottom of the V-groove.
5.
If any belt has stretched and there is no allowance for adjustment, or if there are cuts or cracks on any belt, replace the belt.
6.
When the new belt is set, readjust
AE20937B
3-62
it after operation
for an hour.
24.4.5 CHECK LEVEL OF BAlTERY

Carry out this check before
a
l
operating
ELECTROLYTE
the machine.
WARNING
To avoid gas explosions, 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.
1.
Open the battery
cover.
2.
Remove cap @ and check that the battery electrolyte is up to the

UPPER LEVEL line. If the level is low, add distilled water.
Do not add water above the UPPER LEVEL line. This may cause
leakage of the electrolyte, which may cause fire.
If the battery electrolyte has spilled, have dilute sulphuric acid
added.
3.
When adding distilled water to any cell at cap 0,

water also to the other cells.
4.
Clean the air hole in the battery cap, then tighten the cap
securely.
Wipe the top surface of the battery with a damp cloth to keep it
clean.
add distilled
NOTICE
When adding distilled water in cold weather,
add it before
starting operations in the morning to prevent the electrolyte from
freezing.
3-63
24.4.6 CHECK BRAKE PERFORMANCE
contact
your Komatsu
distributor
for repairs
Before starting the engine, check

machine is safe, then do as follows.
that
immediately.
the
area
around
the
1. Start the engine.

2.
Set safety lever @ to the FREE position then operate blade

control lever and ripper control lever @ to raise the blade and
ripper.
Leave the safety lever to the FREE position.
3.
Set parking
4.
Depress brake pedal @ and move joystick @ to the FORWARD

2nd position.
NOTICE
Do not place the gear shift lever in the 1st speed
Otherwise,
it will cause damage to the machine.
position.
Machines
5.
Operate fuel control lever @ to raise the engine speed gradually

to full throttle.
6.
Check that the machine does not move. This indicates that brake
performance
is normal.
3-64
eauimed
with CanoPY
24. SERVICE
24.5
EVERY 500 HOURS
PROCEDURE
SERVICE
Maintenance
for every 250 hours service should be carried out
at the same time.
24.5.1
REPLACE
FUEL
FILTER
A
l
l
l
CARTRIDGE
WARNING
Engine is at high temperature

immediately
after the machine
has been operated.
Wait for engine to cool down before
replacing the filter.
Do not bring fire or sparks near the fuel.
When bleeding the air, be carefull not to let the fuel overflow.
It may cause a fire.
Prepare
a filter wrench
1. Set the container
and a container
to catch the fuel.
to catch the fuel under the filter cartridge.
2.
Close valve 0.
3.
Remove drain plug @ at the bottom of the filter, and drain the
oil. After draining the oil, tighten drain plug @ again.
4.
Using a filter wrench,

remove it.
turn filter cartridge
@ counterclockwise
to
5.
Clean the filter holder, fill a new filter cartridge with clean fuel,
coat the packing surface with engine oil, then install it to the filter
holder.
6.
When installing, tighten until the packing surface contacts the

seal surface of the filter holder, then tighten it up 3/4 to 1 turn.
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 to the correct amount.
7.
Open valve @ and loosen
8.
Loosen the knob of feed pump @I and move the pump up and
down to draw off fuel until air ceases to come out of plug 0.
air bleeding
plug 0.
3-65
24. SERVICE
9.
PROCEDURE
Tighten air bleed plug 0,

@ and tighten it.
then push in the knob of feed pump
10. After replacing the filter cartridge, start the engine and check that
there is no leakage of oil from the filter seal surface.
REMARK
When only replacing the filter cartridge, it is enough to bleed the
air from the air bleeding plug at the filter head.
However, if the fuel piping is removed, bleed the air also from
the air bleeding valve of the injection pump.
24.5.2 REPLACE TRANSMISSION

FILTER ELEMENT
AND TORQUE CONVERTER OIL FILTER ELEMENT
7
WARNING
Before opening the filter case, depress the brake pedal several
times to release the pressure, then lock the brake pedal. If there
is still pressure inside the filter, the oil may spurt out.
1.
2.
Remove
the floor cover on right side fender.
Remove
bolts @ and cover @ is lifted up, then take out element
0.
Clean the inside of the case and the removed
new elements.
Replace the O-ring at the same time.
parts, and install
AL116560
3-66
24.5.3 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD

OIL
Ah WARNING
There is danger that the oil may spurt out under internal
pressure, so to the side, and gradually turn the plug to release
the internal pressure before removing the plug completely.
1.
Place the machine
on a horizontal
place.
2.
Remove oil level plug @ and check whether the final drive case
is filled with oil to lower edge of the plug hole.
AE209410
3.
AND
If the oil level is still too low, add gear oil through oil level plug
hole @$ until the oil overflows.
Before removing oil level plug 0, remove all the mud and dirt
from around oil oil level plug 0. Be careful not to let any dirt
or sand get in when adding oil.
LUBRICANTS
ACCORDING
3-67
24. SERVICE
PROCEDURE
24.5.4 CHECK, REPLACE FAN BELT

Check the V-belt, and replace the V-belt if the condition
l
l
is as follows.
If the V-belt is in contact with the bottom of the pulley groove.

If the V-belt is worn and has sunk below the outside diameter of
the pulley.
If the V-belt is cracked or peeling
Replacement
When replacing
the V-belt,
do as follows.
1.
Insert bar @ (length approx. 50 cm) into hole @ (o/18)

tension pulley bracket, then pull strongly.
of the
2.
The spring will extend and the tension pulley will move to the
inside, so remove the old belt and install the new one.
Always replace the V-belts as a set (3 belts).

An autotensioner
is installed, so there is no need to adjust the
belt tension until the belt is replaced.
3-68
AE209420
24.6
EVERY 1000 HOURS
SERVICE
Maintenance
for every 250 and 500 hours
carried out at the same time.
service
should
be
24.6.1 CHANGE OIL IN POWER TRAIN CASE, CLEAN

STRAINERS (INCL. TRANSMISSION
CASE,
TORQUE CONVERTER CASE AND BEVEL GEAR
CASE)
g
WARNING

immediately
after the machine
has been operated. Wait for the oil to cool down before starting
the operation.
Prepare the following.
Container to catch drained oil: Min 150 fi capacity
l
Refill capacity: 150 e (39.6 US gal, 33.0 UK gal)
l
1. Remove
the cover on the bottom
of the rear body.
2.
Pull out hose @I slowly to avoid getting

loosen drain plug @ to drain the oil.
3.
After draining,
4.
Insert hose @ inside the cover, then install the cover.
tighten
oil on yourself,
and
drain plug 0.
-(z/l=
5.
Remove
the cover on left fender,
remove
AL116590
bolts @ and case 0.
\\
AE209430
3-69
6.
Take out strainer @ and magnet 8.

If any damage to strainer @ or magnet
a new one.
@ is found,
replace with
7.
Loosen bolt 0, then divide into strainer @ and magnet 8.

Tightening torque of bolt 0: 46 - 59 Nm (4.7 - 5.9 kgm, 34 - 43
Ibft)
8.
Remove all dirt from strainer, then wash in clean diesel oil or
flushing oil.
Clean the case interior and the removed parts.
9.
Install the strainers
to their original
position.
10. After installing, replace the element in the power train oil filter.
For details, see 24.5 EVERY 500 HOURS SERVICE.
L-J
11. Refill the specified
AND
quantity
of engine
oil through
oil filler 0.
LUBRICANTS
ACCORDING
12. Check that the oil is at the specified level.

For details, see 24.2 CHECK BEFORE STARTING.
24.6.2 CHECK, CLEAN FUEL STRAINER

1.
Tighten
2.
Remove cap 0, and wash the strainer and strainer

The strainer forms one unit with the cap.
3.
After checking
tighten cap 0.
4.
After installing,
3-70
valve 0.
and cleaning,
open valve 0.
set the strainer
case.
in the case, then
AE209440
24.6.3 CLEAN STEERING CLUTCH CASE BREATHER

1.
Remove
bolts 0,
then remove
cover 0.
2.
Remove breather @ on steering clutch case, and wash out dust

remaining inside with diesel fuel or flushing oil.
24.6.4 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST

CYLINDER CASE, ADD OIL
1. Remove bolts (iJ, then remove cover 0.
When
in.
removing
the cover, be careful
not to let dirt or sand get
2.
Insert a scale and check that the oil level is 70 - 80 mm (2.6 - 3.2
in) from the bottom edge of the inspection port.
3.
If the oil level is low, add engine oil so that the oil.
Use Class CD SAEIO engine oil regardless of the ambient
perature.
tern-
AE20947B
24 8.6.5 GREASE TENSION
PULLEY ASSEMBLY
1.
Using a grease pump, pump in grease through

shown by arrow.
2.
After
greasing,
wipe
off any old grease
that
the grease fitting
was
pushed
out.
3-71
24. SERVICE
24.6.6
PROCEDURE
CHECK FOR LOOSE ROPS MOUNT
BOLTS
Check for loose and damaged bolts. If any loose bolt is found,
tighten to a torque of 1520 - 1912 Nm (155 - 195 kgm, 1121 - 1410
Ibft).
If any damaged bolt is found, replace the bolt with a genuine
Komatsu bolt.
24.6.7
REPLACE CORROSION
a
RESISTOR CARTRIDGE
WARNING
If the engine has been operated,

all parts will be at a high
temperature,
so never try to replace the cartridge immediately
after stopping the engine.
Always wait for the engine and other parts to cool down.
Container to catch drained
l
Filter wrench
l
coolant
1.
Close valves @ (2 places).
2.
Set a container
3.
Using a filter wrench,
4.
Clean the filter holder, coat the packing surface and thread of the
new cartridge with engine oil, then install it to the filter holder.
5.
When installing, tighten until the packing surface contacts the

seal surface of the filter holder, then tighten it up 2/3 of a turn.
If the filter cartridge is tightened
too far, the packing will be
damaged
and this will lead to leakage of coolant. If the filter
cartridge is too loose, coolant will also leak from the packing, so
always tighten to the correct amount.
6.
Open valves
7.
After replacing the cartridge, start the engine and check for any
leakage of water from the filter seal surface. If there is any water
leakage, check if the cartridge is tightened properly.
24.6.8
to catch the coolant
cartridge
0.
AN167100
@ (2 places).
CHECK ALL TIGHTENING

TURBOCHARGER
Contact your Komatsu
3-72
remove
under the cartridge.
distributor
PARTS OF
for inspection
or adjustment.
24.7
Maintenance
for every 250, 500 and 1000 hours service should
be carried out at the same time.
24.7.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE

HYDRAULIC OIL FILTER ELEMENT

oil. When
removing
immediately
the oil filler cap 0,
after the machine
has
turn it slowly to release

Container to catch drained oil: Min. 120 f? capacity
l
Refill capacity:
120 e (31.68 US gal, 26.4 UK gal)
0
1.
Lower the blade and ripper on the ground securely, stop the
engine and slowly turn the cap of oil filler @ to release the
internal pressure. Then, remove the cap.
2.
Remove drain plug @ at the bottom of the tank and loosen drain
valve 0. After draining the oil, tighten drain plug @ and drain
valve 0. When loosening drain valve 0, be careful not to get oil
on yourself.
3.
Remove bolts 0, lift up cover 0,

valve together with the cover.
4.
Remove nut @ which is tightening

element
removed parts and install new element.
Replace O-ring at the same time.
5.
Add engine
AND
LUBRICANTS
ACCORDING
6.
oil through
and take out element
@ and
@ and clean the
oil filler port @ to the specified
After adding oil, check that the oil is at the specified

details, see 25.4 EVERY 250 HOURS SERVICE.
level.
level. For
AL116710
3-73
24.
SERVICE
PROCEDURE
24.7.2 CHANGE OIL IN FINAL DRIVE CASE
A
l
WARNING

immediately
after the machine
has been operated.
Wait for the oil to cool down before
starting the operation.
There is danger that the internal pressure will cause the oil
to spurt out, so when removing the plug, stand to the side
and turn the plug slowly to release the internal pressure, then
remove the plug carefully.

l
Container to catch drained oil: Min. 65 e capacity
l
Refill capacity:
each 65 e (17.16 US gal, 14.3 UK gal)
1.
Remove oil filler plug 0, then remove drain plugs (iJ, and drain
the oil.
Remove all the mud and dirt from around oil filler plug @ before
removing it. Be careful not to let any dirt or sand get in when
adding oil.
2.
After draining
3.
Refill the engine oil until oil overflows

and tighten the plugs.
AND
3-74
the oil, tighten
the drain plug 0.

from filler plug hole 0,
LUBRICANTS
ACCORDING
24.7.3 CHANGE OIL IN DAMPER CASE, CLEAN AIR HOLE

AND BREATHER
Container to catch drained oil: Min. 2.1 .@capacity
Refill capacity: 2.1 .rZ(0.55 US gal, 0.46 UK gal)
Remove
breather
@ at the top of the damper.
Wash out dust remaining

flushing oil.
inside of breather
@ to the original
with diesel oil and
3.
Install breather
position.
4.
Remove
cover.
air hole plate @ (4 places) from the top of the damper
5.
Remove
flushing
any dirt or dust, then

oil.
6.
Open the inspection
7.
Remove drain plug @ slowly to avoid getting oil on yourself,

drain the oil.
After draining the oil, tighten plug 0.
8.
Pull out dipstick 0,

through oil filler.
wash
it in clean
diesel
oil or
cover under the chassis.

and
AL116760
AND
9.
and add engine
oil to the specified
level
LUBRICANTS
ACCORDING
Check that the oil level is between the H and L marks on dipstick
(iJ For details, see 24.3 CHECK BEFORE STARTING.
10. Close the inspection
cover.
3-75
24. SERVICE
PROCEDURE
24.7.4 CHECK PIVOT BEARING OIL LEVEL, ADD OIL

1.
2.
Remove plug 0.
When removing plug 0,
be careful
not to let dirt or dust get it.
Check that the oil is at the level shown in the diagram. If the oil
level is low, add engine oil through the hole of plug 0.
Use Class
temperature.
CD SAE
30 engine
oil regardless
of the
ambient
A-A
Section
AE20099B
24.7.5 CLEAN ENGINE BREATHER ELEMENT

r
1. Loosen clamp
0,
bolt 0,
then remove
then remove
the hose.
2.
Remove
breather
0.
3.
Wash the whole breather in diesel oil or flushing

it dry with compressed
air.
4.
Replace the breather

and install it.
5.
Check the bleather hose, and if there

inside, replace it with a new hose.
oil, then blow
O-ring with a new part, coat with engine oil,
is any oil sludge
on the
AL116800
3-76
24.7.6 CLEAN, CHECK TURBOCHARGER

distributor
for cleaning
24.7.7 CHECK PLAY OF TURBOCHARGER

distributor
24.7.8 CHECK ALTERNATOR,
or inspection.
ROTOR
to have the play checked.
STARTING
MOTOR
The brush may be worn, or the bearing may have run out of
grease, so contact your Komatsu distributor for inspection or repair.
If the engine is started frequently,
carry out inspection every
1000 hours.
24.7.9 CHECK ENGINE VALVE CLEARANCE,
ADJUST
As special tool is required for removing and adjusting

you shall request Komatsu distributor for service.
the parts,
3-77
24. SERVICE
24.8
PROCEDURE
Maintenance
for every 250, 500, 1000 and 2000
should be carried out at the same time.
hours service
24.8.1
CHECK
WATER
PUMP
Check that there is oil leakage, water leakage, or clogging of
drain hole 0. If any abnormality
is found, contact your Komatsu
distributor for disassembly
and repair or replacement.
24.8.2
CHECK
VIBRATION
DAMPER
Check decrease of damper @ fluid, dent or out-of-flat.
any abnormality,
contact Komatsu distributor for repair.
If there is
24.8.3
CHECK
FAN PULLEY
AND TENSION
PULLEY
Check the pulley for play and leakage of grease. If there is any
abnormality,
please contact your Komatsu distributor for disassembly and repair or replacement.
3-78
24.8.4 CHECK MAIN FRAME, WORK EQUIPMENT

(BLADE, RIPPER)
Main frame
Check after the first 4000 hours, and every 1000 hours after that.
1.
Preparation
Wipe off all the mud that is stuck around portions @ - @ of the
work equipment
and frame to make it easier to carry out the
check.
2.
Visual check
Carefully check the base material of the steel casting and welding at portions @ - 0, and check that there is no damage.
If any cracks or other damage are found, carry out repairs.
i
0A
Please contact your Komatsu

procedure.
distributor
for details of the repair
Blade
Ripper
AE209610
3-79
c)
cn
25. SPECIFICATIONS
OPERATING
WEIGHT
(with semi-U
(without
dozer, variable
operator)
multi
67500
kg (148838
lb)
ripper, 610 mm (24 in) shoe, ROPS cab, and air conditioner)
PERFORMANCE
Forward
1st
3.8 km/h (2.4 MPH)
2nd
6.8 km/h (4.2 MPH)
I
l
Travel
speed
Reverse
3rd
11.8 km/h (7.3 MPH)
1st
5.1 km/h (3.2 MPH)
2nd
9.2 km/h (5.7 MPH)
3rd
BLADE (semi-U
blade)
Weight of attachment
and cylinder support)
Max. tilt
Weight
Digging
(incl. tilt cylinder
10540 kg (23241
lb)
1065 mm (3 ft 6 in)
RIPPER (variable
l
15.8 km/h (9.8 MPH)
giant ripper)
of attachment
angle
6720 kg (14818
Standard 45 (possible
32.5 and 55.5)
lb)
to adjust steplessly
TOWING
l
Towing
force
48500
kg (475623
N)
ENGINE
l
Model
Flywheel
Maximum
0 Starting
l
Alternator
Battery
4-2
Komatsu
horsepower
torque
motor
SAGD170E-2
diesel engine
386 kW (525 HP)/1800
rpm
2648 Nm (270 kgm)/l300
rpm
24 V 7.5 kW x 2 pieces
24 V
12 V
50 A
170 Ah x 2 pieces
between
25. SPECIFICATIONS
Semi-U
tilt dozer + variable
U tilt dozer + variable
multi
multi
ripper
ripper
*;/
3815(12'6*
r
Overall
length
)
10405(3411')
3160(
10' 4' )"
__
,
-
?
A0209638
4-3
25. SPECIFICATIONS
3815(12'6"
Overall
length
5770(18'11')
10209646
4-4
OPTIONS, ATTACHMENTS
26.1
PRECAUTIONS
RELATED TO SAFETY
If attachments
or options other than those authorized by Komatsu are installed, this will not only
affect the life of the machine, but will also cause problems with safety.
When installing attachments
not listed in this Operation and Maintenance
Manual, please contact
your Komatsu distributor first.
If you do not contact Komatsu, we cannot accept any responsibility
for any accident or failure.
WARNING
Precautions for removal and installation

operations
When removing or installing attachments,
obey the following
safety during the operation.
e Carry out the removal
and installation
operations
precautions
and take care to ensure
on a flat, firm ground
When the operation is carried

during the operation.
out by two
When
(more than 25 kg (55 lb)), use a crane.
When removing heavy parts, always support the part before removing it.
When lifting such heavy parts with a crane, always pay careful attention to the position
center of gravity.
carrying
heavy objects
or more workers,
It is dangerous to carry out operations

stand, and check that it is safe.
When removing
not fall over.
Never go under a load suspended front a crane.

Always stand in a position that is safe even if the load should
or installing
Qualifications
are
unqualified person.
For details
5-2
required
of the removal
with
determine
surface.
attachments,
to operate
and installation
the load kept suspended.
signals and follow
Always
Never
operations,
allow
of the
set the load on a
make sure that they are in a stable condition
a crane.
these
and will
fall.
the
please contact
crane
to be operated
your Komatsu
by an
distributor.
27. USING SEAT BELT
When operating
the seat belt.
l
l
l
a machine
equipped
WARNING
with ROPS, be sure to use
Before fastening the seat belt, inspect the securing brackets

and belt for abnormal conditions.
Replace any worn or damaged
seat belt or the securing
brackets.
Adjust and fasten the seat belt before operating the machine.
Always use seat belt when operating the machine.
Fit the seat belt across your lap without twisting.
27.1
FASTEN THE BELT AND REMOVE

FOLLOWING MANNER
IT IN THE
Adjust the seat so that the brake pedal can be depressed

way with the operators back against the backrest.
all the
After positioning the seat, adjust the tether belt 0. With the seat
unoccupied, tense the belt slightly across the seat and install.
Sit in the seat, hold tongue @ of reel 0, and pull the belt out
slowly to a length which fully covers your lap.
Insert tongue @ into buckle @ and push until there is a click. Pull
back reel @ until the belt fits securely across your lap. In this
condition, the lock is applied to prevent the belt from extending
any further.
Fit the seat belt across your lap without twisting.
REMARK
If the lock is applied before the tongue is installed into the buckle,
return the belt to the reel, then carry out the operation again from
the beginning.
5.
Tense the belt and check that the lock is applied.
6.
To remove the belt, press the red button on buckle 0.

will automatically
wind in.
The belt
Inspect bolts and fittings on the chassis for tightness. Retighten

any loose bolts to 19.6 to 29.4 Nm (2 to 3 kgm, 14.5 to 21.7 Ibft)
torque.
If the seat is scratched or frayed or if any of the fittings are
broken or deformed from long service, replace the seat belt immediately.
5-3
28. SELECTION OF TRACK SHOE
28.1 SELECTION
Select suitable
OF TRACK SHOES
track shoes to match the operating
conditions.
METHOD OF SELECTING SHOES

If a wider shoe than necessary is used, the load on the track will increase, and this will cause the shoes
to bend, links to crack, pins to break,~shoe bolts to come loose, and various other problems.
Category
Use
Bedrock,
normal soil
Precautions
5-4
Normal
Soft soil
soil
using
Track shoe width
This shoe can be used for a wide range of work from

crushed rock to general civil engineering
work such as
reclamation
of residential land. There is no particular
limit to its use.
Use this shoe for general
when
soil, such as where
610 mm (24 in)
the
main work is scraper work and pusher work, reclaiming

land for golf courses, or stripping the overburden
for coal
mines. This shoe cannot be used on bedrock. On jobsites
where there are rocks in the soil, be careful to avoid
letting the machine mount the rocks.
Use this shoe on soft ground where the shoe in category
B sinks into the ground. Do not use this shoe on jobsites
where there are rocks in the soil.
610 mm (24 in)
710 mm (28 in)

810 mm (32 in)
Procedure
Suitable
point
Typical
rock
Check
Procedure
Features
Part No.
Shape
Point @
Non-symmetrical
shape
0 Yellow
a Short
195-78-71420
ALl16620
+@J~~~+$ZJ~~
Features
195-78-71320
ALIl6620
Hard
Point @
Non-symmetrica
shape
0 Yellow
l Short
l
No
195-78-71370
Medium
195-78-71340
AL116650
Point @
Non-symmetrica
shape
0 Yellow
0 Long
l
granite,
Soft e
Yes
chest
Hard
v
Does it penetrate ?
(Can it be used
to end ?)
No
v
195-78-71350
AL116650
195-78-71330
AL116620
Point @
Non-symmetrica
shape
a Red
l Short
l
195-78-71390
AL116640
Point @
l Symmetrical
shape
a Red
l Short
Proportion of quartz is not so high (40% - 70%)

Rock is not in layers or seams, so heat is generated
at point, point wear rapidly, ripping is difficult
Point @
Non-symmetrica
shape
a Red
0 Long
l
Basalt, andesite,
No
Install point 0
Install point @
v
Do impact force
cause breakage ?
No (Less than 70%)
v
Does impact
force cause
breakage ?
0 Proportion of
quartz is high
(70% - 95%),
point wears
rapidly
Sandstone
Soft -
No
1 Install point @ 1
Yes (Over 70%)

(Whole point is
worn evenly)
Dose rock have high

quartz contents ?
Install
standard
point @
AL116640
Point @
Symmetrical
shape
0 Yellow
l Short
l
rock
v
Does it penetrate ?
(Can it be used
to end ?)
No
cracks produced
No v
All type of general
Soft p
<
point Q 1
1Is wear fast ?
[ Install standard
Yes
0 Little quartz,
little wear
l Deposited
in
layers, so ripping
is easy
Type of rock Shale, limestone
Hardness
penetration
Check for cracks

or breakage
Procedure
Check wear
Procedure
30. HANDLING
30.1
OPENING
CAP WITH LOCK
AND CLOSING
LOCKABLE CAP
Lock-type caps are available for the radiator water filler cap, fuel
tank filler cap, power train case oil filler cap, hydraulic tank oil filler
cap, and hydraulic tank breather cap. The cap opening and closing
method is as follows.
WHEN OPENING CAP

1. Insert the key. Make sure that you have inserted the key fully
before turning it. If the key is turned when only partially inserted,
it may break.
2.
Turn the key counterclockwise

to align the match mark on the
cap with the rotor groove, then turn the cap slowly. When a click
is heard, the lock is released, enabling the cap to be opened.
180
houlder
AD053810
TO LOCK THE CAP

1. Turn the cap into place.
2.
Turn the key clockwise
REMARK
When
open.
5-6
the cap is locked,
and take the key out.
it can be turned
freely,
but it will not
AD053820
31. E6oFZEECRTVE
METHOD OF OPERATION
31 .I
FOR DUAL TILT
BLADE CONDITION
Operating
Single tilt
l
Normal
method
Applicable
l
Normal
operation
Blade position
operations
tilt operation
AE209650
Dual tilt
Turn the dual button ON
and carry out tilt operation
l
l
Digging up boulders
Side cutting operations (high
places)
Horizontal dozing operations from
side slope (rough ground)
Ditching operations
Hauling
Dozing soft soil (filling)
Leveling operations (spreading)
Side-cutting operations
R pitch (pitch back)

Turn the pitch button ON
and carry out left tilt
operations
AE209670
S pitch (standard)
Normal
F pitch (pitch dump)

Turn the pitch button ON
and carry out right tilt
operations
Digging natural ground and bedrock (digging hard soil)

Pushing soil over cliffs
Pushing-up soil
(Reduces spillage of soil over the
top surface of the blade, and
reduces amount of soil carried
back)
l
l
operations
AE209690
5-7
31. EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER
31.2
DOZING
WORK
31.2.1 DOZING ON LEVEL GROUND

Natural
ground,
OR DOWNHILL
bedrock
Forward
Ditch
2. Haul
ing
3. OumDing
AE20970B
WARNING
If you feel that the situation is dangerous when dumping the

soil, for safety reasons, use two movements
to push the soil
over the edge.
Dig with the F (Forward) pitch, and when the load on the blade
is approx. 80%, return to S (Straight) pitch and continue digging.
Set to R (Rear) pitch which gives a larger load, and haul the soil.
Adjust the cutting angle to the most effective angle for rolling the
soil.
Use F pitch to dump
5-8
the soil.
Filling, soft soil

Carry out digging
in R pitch or S pitch, and haul in R pitch.
REMARK
If the digging is carried out in R pitch, there is no sudden digging
into the soil, and the operation can be carried out smoothly.
Hard soil (hard clay, shale, etc.)

If digging is carried out in F pitch, and the chassis is raised and
the blade is tilted, the end bit will dig in better.
5-9
31. EFFECTIVE
METHOD
OF OPERATION
FOR DUAL TILT DOZER
31.2.2 PUSHING-UP SOIL
Forward
Rear
Ditch
1.
Dig with S pitch

When digging gradually, use R pitch.
If the ground is hard, use F pitch.
2.
Haul with R pitch.

If there is any spillage
to S pitch.
3.
5-10
of soil over the top of the blade, change
Dump the soil with F pitch.

This dumps the soil more effectively,
after dumping.
and less soil is carried back
pitch
31.3
LEVELING
(SPREADING)
OPERATIONS
Carry out this operation with R pitch.

When carry out this operation with R pitch, the end bit does not
dig in, and the ground can be leveled (or the soil can be spread)
smoothly.
REMARK
If the tilt cylinder is moved completely to the end of its stroke,
the tilt operation cannot be carried out on one side, so move the
cylinder back slightly from the end of its stroke to the S pitch
position.
31.4
DITCHING
OPERATIONS
If the dual tilt is used, the digging width becomes smaller

a deeper ditch can be dug.
If R pitch is used, the digging can be carried out gradually,
this reduces the unevenness.
31.5
BOULDER
RAISING
and
and
OPERATIONS
Because the dual tilt greatly increases the amount of tilt, the
blade can dig in deep and hook under the boulder. In addition, the
operating stroke is large, so operations to raise boulders can be
carried out effectively.
It_
---J&
AE20974B
31.6
SIDE-CUTTING
OPERATIONS
Carry out this operation in R pitch, and set the end face of the
end bit in contact with the rock face to carry out cutting.
AE209750
REMARK
With the dual tilt it is possible to increase the amount
to carry out side-cutting operations on higher walls.
of tilt and
AE209760
5-11
31.7
HORIZONTAL DOZING OPERATIONS

FROM SIDE SLOPE (ROUGH GROUND)
The ! dual tilt can give a larger amount of tilt, so when dozing
from a side slope, this is effective because the chassis becomes
horizontal after a short digging distance.
AE209770
5-12
D375A-3
Form No.
BULLDOZER
SEAM010801
1997 KOHAlkU
All Rights
09-97
(01-l)
Reserved
Komatsu America international Company

440 North Fairwav Drive
I
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
PROPOSAL
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR

2
NAME OF COMPANY:
PHONE NO:
:
S
DEPARTMENT:
E
R
NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE:

Sead 010801

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Copyright 1997 Komatsu America International Company

Unsafe use of thii machine may cause serious injury or death.

This manual provides rules and guidelines

and could result in serious

can cause a serious accident,

of safety is given in SAFETY INFORMATION

on page O-2 and in SAFETY from page

are known to the State

to cause cancer, birth

Safety precautions are described in SAFETY from page l-l.

Your Komatsu machine has been thoroughly

4. LOCATION OF PLATES, TABLE TO ENTER

SERIAL NO. PLATE POSITION

at the right side of blade back surface.

at the left side surface

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

RIPPER SERIAL NO. PLATE POSITION

BLADE SERIAL NO. PLATE POSITION

SERIAL NO. PLATE POSITION

On the upper left side of the engine

for your machine:

serial No. and distributor

Position for attaching safety labels ................................................................................................

Content and use of warning plates .......................................................................................

15. Long-term storage .............................................................................................................................

18. Outlines of service ............................................................................................................................

parts list ...................................................................................................................................

20. Use of fuel, coolant

21. Standard tightening

24. Service Procedure . .. . .. . . . . . . . . .. .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . .. .. . . . . . . . . . .. .. . .. . . . . . .. .. . . . . . . . . . .. . . . . . . . . . .. .. . . . .. .. . .. . . . . . ......

27. Using seat belt ..................................................................................................................................

28. Selection of track shoe .....................................................................................................................

29. Procedure for selecting ripper point.. ..............................................................................................

30. Handling cap with lock ......................................................................................................................

31. Effective method of operation for dual tilt.. ...................................................................................

Read and follow all safety precautions.

Follow all safety rules, precautions

When working with another operator or a person

traffic duty, be sure all personnel

Be sure all guards and covers are in their proper position.

use of safety features

such as the safety lock and seat belts properly.

NEVER remove any safety features. ALWAYS keep them

could result in serious

WARNING: Failure to follow these safety precautions may lead

Before making a modification,

To avoid hitting unlocked

levers, before standing

Move joystick to neutral

and move SAFETY

left of seat) to LOCK position.

can cause serious

seat, do the following:

right of seat) to LOCK

use the points marked with arrows in the diagram below.

A WARNING: Failure to follow these safety precautions may lead

FIRE PREVENTION FOR FUEL AND OIL

BURN HAZARD PREVENTION

To prevent hot water from spurting out:

To prevent hot oil from spurting out:

ASBESTOS DUST HAZARD PREVENTION

If you handle materials containing asbestos fibers, follow these guidelines

A JHJize Ps;;ereasons of safety, always