Operation & EEAM022804

Maintenance Manual

D85EX-15
D85PX-15
BULLDOZER
SERIAL NUMBER
D85EX-15 - 10001 and up
D85PX-15 - 1001 and up

WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
FOREWORD
11
FOREWORD FOREWORD

FOREWORD 0.
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-
dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
and maintenance.

WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.

Always be sure to read and understand this manual thoroughly before performing operation and
maintenance.

Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.

Keep this manual at the storage location for the Operation and Maintenance Manual given below, and
have all personnel read it periodically.

If this manual has been lost or has become dirty and cannot be read, request a replacement manual
immediately from Komatsu or your Komatsu distributor.

If you sell the machine, be sure to give this manual to the new owners together with the machine.

Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operat-
ing the machine.

Location to Keep Operation & Maintenance Manual

In Door Pocket Inside of Cab Door

1-2
FOREWORD SAFETY INFORMATION

SAFETY INFORMATION 0.
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.

Signal words

The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

Indicates an imminently hazardous situation which, if not avoided, will result in death
DANGER or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death
WARNING or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or
CAUTION moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.

Example of safety message using signal word

WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or
death.

Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is useful to know.

This word is used for precautions that must be taken to avoid actions which could shorten
NOTICE the life of the machine.

REMARKS This word is used for information that is useful to know.

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SAFETY INFORMATION FOREWORD

Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to indicate safety procedures.

Example of safety label using words

Part No.
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side, and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.

Part No

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi-
bility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.

The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of
your machine or for questions regarding information in this manual.

The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))

1-4
FOREWORD SAFETY INFORMATION

Noise emission levels 0.

Two labels indicating the machine noise level are affixed on the
machine.
Sound pressure level at the operator's station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle)

Sound power level emitted by the machine, measured

according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.

Vibration levels 0.
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera-
tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.

If equipped with air suspension seat

The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is less than or equal to 0.5 m/s².

If equipped with mechanical suspension seat

The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is 0.52 m/s².

These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.

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SAFETY INFORMATION FOREWORD

Operating condition:
(WHEEL LOADER:) V-shape loading

(HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating)

(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion

(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading, and
travelling without load)

Guide to Reduce Vibration Levels on Machine

The following guides can help an operator of this machine to reduce the whole body vibration levels:

1. Use the correct equipment and attachments.

2. Maintain the machine according to this manual

Tire pressures (for wheeled machines), tension of crawler (for crawler machines)
Brake and steering systems
Controls, hydraulic system and linkages

3. Keep the terrain where the machine is working and traveling in good condition
Remove any large rocks or obstacles
Fill any ditches and holes
Site manager should provide machine operators with machine and schedule time to maintain terrain condi-
tions

4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
Adjust the seat and suspension for the weight and size of the operator
Wear seat belt
Inspect and maintain the seat suspension and adjustment mechanisms

5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly

6. Adjust the machine speed and travel path to minimize the vibration level
When pushing with bucket or blade, avoid sudden loading; load gradually
Drive around obstacles and rough terrain conditions
Slow down when it is necessary to go over rough terrain
Make the curve radius of traveling path as large as possible
Travel at low speed when traveling around sharp curves

7. Minimize vibrations for long work cycle or long distance traveling

Reduce speed to prevent bounce
Transport machines long distances between worksites

8. The following guidelines can be effective to minimize risks of low back pain
Operate the machine only when you are in good health.
Provide breaks to reduce long periods of sitting in the same posture
Do not jump down from the cab or machine
Do not repeatedly handle and lift loads

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FOREWORD INTRODUCTION

INTRODUCTION 0.
This Komatsu machine is designed to be used mainly for the following work:
Dozing
Cutting into hard or frozen ground or ditching
Felling trees, removing stumps
Pushing
Ripping
For further details, see “WORK POSSIBLE USING BULLDOZER ( 3-92 )“.

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 0.

Front

Left Right

Operator’s seat

Sprocket
Rear

In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.

1-7
NECESSARY INFORMATION FOREWORD

NECESSARY INFORMATION 0.
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.

MACHINE SERIAL NO. PLATE AND POSITION 0.

Under the front of the console box on the right side of the operator's seat.

ENGINE SERIAL NO. PLATE AND POSITION 0.

This is at the rear of the starting motor on the rights side of the engine.
(The EMISSION CONTROL INFORMATION LABEL is at the front surface of the engine oil filler on the left side of
the engine.)

EPA: Environmental Protection Agency, U.S.A.

1-8
FOREWORD NECESSARY INFORMATION

BLADE SERIAL NO. PLATE POSITION 0.

This is located at the upper right of blade back surface.

RIPPER SERIAL NO. PLATE POSITION 0.

This is located at the left side surface of ripper beam.

ROPS, FOPS NO. PLATE POSITION 0.

This is located at the top left.
ROPS
FOPS

POSITION OF SERVICE METER 0.

On top of the machine monitor

1-9
NECESSARY INFORMATION FOREWORD

TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR 0.

Machine serial No.

Engine serial No.

Product Identification Number

Manufacturers name: KOMATSU LTD.

Address: 3-6 Akasaka
Minato-ku, 101 Tokyo
Japan

Distributor
Address

Phone

Service personnel for your

machine:

1-10
FOREWORD NECESSARY INFORMATION

MACHINE SERIAL NUMBER PLATE

Valid until 31 December 2003

Model

Seriel Number

Manufacturing year
Weight

Engine power Komatsu Ltd. Tokyo, Japan

Manuafacturer

Produced by Komatsu Tokyo, Japan

Valid as of 1 January 2004

Model

Seriel Number

Manufacturing year

Weight
Engine power

Product Identification Number

Manuafacturer

1-11
CONTENTS

CONTENTS

FOREWORD
FOREWORD ......................................................................................................................................................... 1-2

SAFETY INFORMATION...................................................................................................................................... 1-3

Noise emission levels ................................................................................................................................. 1-5
Vibration levels............................................................................................................................................ 1-5
Guide to Reduce Vibration Levels on Machine.................................................................................. 1-6

INTRODUCTION................................................................................................................................................... 1-7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE ....................................................................... 1-7

NECESSARY INFORMATION ............................................................................................................................. 1-8

MACHINE SERIAL NO. PLATE AND POSITION ....................................................................................... 1-8
ENGINE SERIAL NO. PLATE AND POSITION .......................................................................................... 1-8
BLADE SERIAL NO. PLATE POSITION .................................................................................................... 1-9
RIPPER SERIAL NO. PLATE POSITION ................................................................................................... 1-9
ROPS, FOPS NO. PLATE POSITION ........................................................................................................ 1-9
POSITION OF SERVICE METER .............................................................................................................. 1-9
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................ 1-10
MACHINE SERIAL NUMBER PLATE....................................................................................................... 1-11

SAFETY
SAFETY ................................................................................................................................................................ 2-2

SAFETY LABELS................................................................................................................................................. 2-4

POSITIONS OF SAFETY PICTOGRAMS .................................................................................................. 2-4
SAFETY LABELS ....................................................................................................................................... 2-5

GENERAL PRECAUTIONS ................................................................................................................................. 2-9

PRECAUTIONS FOR OPERATION ................................................................................................................... 2-16

BEFORE STARTING ENGINE ................................................................................................................. 2-16
OPERATION ............................................................................................................................................. 2-17
TRANSPORTATION................................................................................................................................. 2-20
BATTERY ................................................................................................................................................. 2-20
TOWING ................................................................................................................................................... 2-22

PRECAUTIONS FOR MAINTENANCE .............................................................................................................. 2-23

OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2

1-12
 CONTENTS

GENERAL VIEW OF MACHINE ................................................................................................................. 3-2

GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3

EXPLANATION OF COMPONENTS.................................................................................................................... 3-5

FRONT PANEL........................................................................................................................................... 3-5
CHECK MONITOR GROUP .............................................................................................................. 3-7
CAUTION MONITOR GROUP .......................................................................................................... 3-8
EMERGENCY CAUTION ITEMS .................................................................................................... 3-10
METER GROUP .............................................................................................................................. 3-12
SWITCH........................................................................................................................................... 3-16
LAMP ............................................................................................................................................... 3-19
METHOD OF USING DISPLAY PANEL B (Multi-information) ........................................................ 3-21
SWITCH.................................................................................................................................................... 3-28
CONTROL LEVERS, PEDALS ................................................................................................................. 3-31
DUST INDICATOR ................................................................................................................................... 3-36
FUSE BOX................................................................................................................................................ 3-37
CIRCUIT BREAKER ........................................................................................................................ 3-38
FUSE CAPACITY AND NAME OF CIRCUIT................................................................................... 3-38
FUSIBLE LINK .......................................................................................................................................... 3-39
DOOR OPEN LOCK ................................................................................................................................. 3-40
SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-40
DOOR POCKET ....................................................................................................................................... 3-41
ASHTRAY ................................................................................................................................................. 3-41
CAR STEREO, HANDLING ...................................................................................................................... 3-42
EXPLANATION OF COMPONENTS............................................................................................... 3-42
METHOD OF OPERATION ............................................................................................................. 3-47
PRECAUTION WHEN USING......................................................................................................... 3-49
AIR CONDITIONER.................................................................................................................................. 3-50
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ................................................ 3-50
METHOD OF OPERATION ............................................................................................................. 3-52
PRECAUTIONS WHEN USING ...................................................................................................... 3-53
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE .......... 3-53
CHECKS DURING OFF-SEASON .................................................................................................. 3-53
PROCEDURE FOR REPLACING RECEIVER ................................................................................ 3-53
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................ 3-54
CLEANING AIR FILTER .................................................................................................................. 3-54
ACCUMULATOR, HANDLING.................................................................................................................. 3-54
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH
ACCUMULATOR ............................................................................................................................. 3-54

OPERATION....................................................................................................................................................... 3-55
CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-55
WALK-AROUND CHECK ................................................................................................................ 3-55
CHECK BEFORE STARTING ......................................................................................................... 3-56
ADJUSTMENT................................................................................................................................. 3-65
OPERATIONS AND CHECKS BEFORE STARTING ENGINE....................................................... 3-69
STARTING ENGINE ................................................................................................................................. 3-71
NORMAL STARTING ...................................................................................................................... 3-71

1-13
CONTENTS

STARTING IN COLD WEATHER .................................................................................................... 3-72

OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................................................... 3-75
BREAKING IN THE MACHINE ........................................................................................................ 3-75
NORMAL OPERATION ................................................................................................................... 3-75
IN COLD AREAS ............................................................................................................................. 3-77
STOPPING ENGINE................................................................................................................................. 3-78
CHECK AFTER STOPPING ENGINE ...................................................................................................... 3-78
MOVING MACHINE OFF.......................................................................................................................... 3-79
STOPPING MACHINE.............................................................................................................................. 3-81
SHIFTING GEAR ...................................................................................................................................... 3-82
SHIFTING BETWEEN FOEWARD AND REVERSE ................................................................................ 3-84
STEERING MACHINE .............................................................................................................................. 3-86
NORMAL TURNING ........................................................................................................................ 3-86
TURNING WHILE DESCENDING A SLOPE................................................................................... 3-87
PRECAUTIONS FOR OPERATION ......................................................................................................... 3-88
PAY ATTENTION TO GAUGES ...................................................................................................... 3-88
PERMISSIBLE WATER DEPTH...................................................................................................... 3-88
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.......................................................... 3-88
PRECAUTIONS ON SLOPE ........................................................................................................... 3-88
METHOD OF USING BRAKES ....................................................................................................... 3-88
PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS ........................................... 3-89
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-89
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY....................... 3-89
PARKING MACHINE ................................................................................................................................ 3-89
CHECK AFTER FINISHING WORK ......................................................................................................... 3-91
LOCKING.................................................................................................................................................. 3-91
WORK POSSIBLE USING BULLDOZER ................................................................................................. 3-92
DOZING ........................................................................................................................................... 3-92
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING .................................................... 3-92
FELLING TREES, REMOVING STUMPS ....................................................................................... 3-92
PUSHER OPERATIONS ................................................................................................................. 3-92
SMOOTHING................................................................................................................................... 3-93
ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................... 3-94
BLADE ADJUSTMENT .................................................................................................................... 3-94
However, the more the digging angle is changed, the more the change becomes in the amount of tilt on the
left and right sides provided by the tilt cylinder. ........................................................................................ 3-95
ADJUSTING RIPPER ...................................................................................................................... 3-96
TIPS FOR LONGER UNDERCARRIAGE LIFE ........................................................................................ 3-98
OPERATION METHOD ................................................................................................................... 3-98
INSPECTION AND ADJUSTING ..................................................................................................... 3-98
INSPECTION AND REPAIR ............................................................................................................ 3-99

TRANSPORTATION......................................................................................................................................... 3-100
TRANSPORTATION PROCEDURE ....................................................................................................... 3-100
LOADING, UNLOADING WORK ............................................................................................................ 3-100
PRECAUTIONS FOR LOADING ............................................................................................................ 3-100
METHOD OF LIFTING MACHINE .......................................................................................................... 3-101

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 CONTENTS

PRECAUTIONS FOR TRANSPORTATION ........................................................................................... 3-102

TRAVELING ON ROADS ....................................................................................................................... 3-102
REMOVAL OF CAB ................................................................................................................................ 3-102
INSTALLATION OF CAB ........................................................................................................................ 3-103
INSTALLATION OF ROPS ..................................................................................................................... 3-103

COLD WEATHER OPERATION ...................................................................................................................... 3-104

PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................ 3-104
FUEL AND LUBRICANTS ............................................................................................................. 3-104
COOLANT ..................................................................................................................................... 3-104
BATTERY ...................................................................................................................................... 3-104
AFTER COMPLETION OF WORK ......................................................................................................... 3-105
AFTER COLD WEATHER ...................................................................................................................... 3-105

LONG-TERM STORAGE.................................................................................................................................. 3-106

BEFORE STORAGE............................................................................................................................... 3-106
DURING STORAGE ............................................................................................................................... 3-106
AFTER STORAGE.................................................................................................................................. 3-106

TROUBLESHOOTING...................................................................................................................................... 3-107
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-107
PROCEDURE FOR BLEEDING AIR ............................................................................................. 3-107
METHOD OF TOWING MACHINE ......................................................................................................... 3-108
IF BATTERY IS DISCHARGED.............................................................................................................. 3-109
STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-109
OTHER TROUBLE ................................................................................................................................. 3-112
ELECTRICAL SYSTEM................................................................................................................. 3-112
MONITOR PANEL ......................................................................................................................... 3-113
CHASSIS ....................................................................................................................................... 3-114
ENGINE ......................................................................................................................................... 3-116

MAINTENANCE
GUIDES TO MAINTENANCE............................................................................................................................... 4-2

OUTLINES OF SERVICE ..................................................................................................................................... 4-5

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ..................................................... 4-5
OIL ..................................................................................................................................................... 4-5
FUEL.................................................................................................................................................. 4-5
COOLANT ......................................................................................................................................... 4-5
GREASE............................................................................................................................................ 4-6
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) .................................................................... 4-6
STORING OIL AND FUEL................................................................................................................. 4-7
FILTERS ............................................................................................................................................ 4-7
OUTLINE OF ELECTRIC SYSTEM............................................................................................................ 4-7

WEAR PARTS LIST ............................................................................................................................................. 4-8

WEAR PARTS LIST.................................................................................................................................... 4-8

1-15
CONTENTS

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................... 4-9

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ........................................................... 4-9

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-13

TORQUE LIST .......................................................................................................................................... 4-13

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-14

SAFETY CRITICAL PARTS...................................................................................................................... 4-15

MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-17

MAINTENANCE SCHEDULE CHART ...................................................................................................... 4-17
INTIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS) ...................................... 4-17
WHEN REQUIRED .......................................................................................................................... 4-17
CHECK BEFORE STARTING ......................................................................................................... 4-17
EVERY 250 HOURS SERVICE ....................................................................................................... 4-17
EVERY 500 HOURS SERVICE ....................................................................................................... 4-17
EVERY 1000 HOURS SERVICE ..................................................................................................... 4-18
EVERY 2000 HOURS SERVICE ..................................................................................................... 4-18
EVERY 4000 HOURS SERVICE ..................................................................................................... 4-18
EVERY 8000 HOURS SERVICE ..................................................................................................... 4-18

SERVICE PROCEDURE .................................................................................................................................... 4-19

INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)............................................... 4-19
WHEN REQUIRED ................................................................................................................................... 4-19
CHECK BEFORE STARTING .................................................................................................................. 4-37
EVERY 250 HOURS SERVICE ................................................................................................................ 4-38
EVERY 500 HOURS SERVICE ................................................................................................................ 4-45
EVERY 1000 HOURS SERVICE .............................................................................................................. 4-49
EVERY 2000 HOURS SERVICE .............................................................................................................. 4-53
EVERY 4000 HOURS SERVICE .............................................................................................................. 4-58
EVERY 8000 HOURS SERVICE .............................................................................................................. 4-61

SPECIFICATIONS
SPECIFICATIONS ................................................................................................................................................ 5-2

ATTACHMENTS, OPTIONS
GENERAL PRECAURIONS ................................................................................................................................. 6-2
PRECAUTIONS RELATED TO SAFETY ................................................................................................... 6-2

SELECTION OF TRACK SHOE ........................................................................................................................... 6-3

SELECTION OF TRACK SHOES ............................................................................................................... 6-3

PROCEDURE FOR SELECTING RIPPER POINT............................................................................................... 6-4

PROCEDURE FOR SELECTING RIPPER POINT..................................................................................... 6-4

1-16
 CONTENTS

CAP WITH LOCK, HANDLING ............................................................................................................................ 6-5

METHOD OF OPENING AND CLOSING CAP WITH LOCK...................................................................... 6-5

INDEX

COLOPHON

1-17
CONTENTS

1-18
 SAFETY
22

WARNING
Please be sure that you fully understand this manual and the
precautions discribed in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precaustions strictly.
SAFETY SAFETY

SAFETY 0.
Safety Labels ........................................................................................................................................................ 2-4
Positions of Safety Pictograms ...................................................................................................................... 2-4
Safety Labels ................................................................................................................................................. 2-5

General Precautions
Safety Rules................................................................................................................................................... 2-9
If Abnormalities Are Found............................................................................................................................. 2-9
Clothing and Personal Protective Items ......................................................................................................... 2-9
Fire Extinguisher and First Aid Kit.................................................................................................................. 2-9
Fafety Features .............................................................................................................................................. 2-9
Keep Machine Clean...................................................................................................................................... 2-9
Inside Operator's Compartment ................................................................................................................... 2-10
Always Apply Lock When Leaving Operator's Seat ..................................................................................... 2-10
Handrails and Steps..................................................................................................................................... 2-11
Mounting and Dismounting .......................................................................................................................... 2-11
No People on Attachments .......................................................................................................................... 2-11
Prevention of Burns...................................................................................................................................... 2-12
Fire Prevention............................................................................................................................................. 2-12
Action If Fire Occurs..................................................................................................................................... 2-13
Window Washer Liquid ................................................................................................................................ 2-13
Pecautions for ROPS ................................................................................................................................... 2-13
Precautions for Attachments ........................................................................................................................ 2-13
Cab Window Glasses................................................................................................................................... 2-13
Unauthorized Modification............................................................................................................................ 2-13
Safety at Worksite ........................................................................................................................................ 2-14
Working on Loose Ground ........................................................................................................................... 2-14
Do Not Go Close to High-Voltage Cables .................................................................................................... 2-14
Ensure Good Visivility .................................................................................................................................. 2-15
Ventilation for Enclosed Areas ..................................................................................................................... 2-15
Checking Signalman's Signals and Signs .................................................................................................... 2-15
Be Careful About Asbestos Dust.................................................................................................................. 2-15

Precautions for Operation ................................................................................................................................... 2-16

Before Starting Engine ................................................................................................................................. 2-16
Checks Before Starting Engine ............................................................................................................. 2-16
Precautions When Starting ................................................................................................................... 2-16
Precautions in Cold Areas .................................................................................................................... 2-17
Operation ..................................................................................................................................................... 2-17
Checks Before Operation...................................................................................................................... 2-17
Precautions When Moving Machine Forward or in Reverse ........................................................................ 2-17
Precautions When Traveling ................................................................................................................. 2-18
Traveling on Slopes .............................................................................................................................. 2-18
Prohibited Operations ........................................................................................................................... 2-19
Useing Brakes....................................................................................................................................... 2-19
Operate Carefully on Snow ................................................................................................................... 2-19
Parking Machine ................................................................................................................................... 2-19
Transportation .............................................................................................................................................. 2-20
Shipping ................................................................................................................................................ 2-20
Battery.......................................................................................................................................................... 2-20
Battery Hazard Prevention.................................................................................................................... 2-20
Starting with Booster Cable .................................................................................................................. 2-21
Towing.......................................................................................................................................................... 2-22
When Towing ........................................................................................................................................ 2-22

Precautions for Maintenance .............................................................................................................................. 2-23

Warning Tag................................................................................................................................................. 2-23
Keep Work Place Clean and Tidy ................................................................................................................ 2-23

2-2
SAFETY SAFETY

Appoint Leader When Working with Others................................................................................................. 2-23

Stop Engine Before Carrrying Out Inspection and Maintenance ................................................................. 2-24
Two Workers for Maintenance when Engine is Running ............................................................................. 2-24
Proper Tools ................................................................................................................................................ 2-25
Handling Accumulator.................................................................................................................................. 2-25
Personnel..................................................................................................................................................... 2-25
Attachments ................................................................................................................................................. 2-25
Work Under the Machine ............................................................................................................................. 2-26
Noise............................................................................................................................................................ 2-26
Precautions When Using Hammer............................................................................................................... 2-26
Repair Welding ............................................................................................................................................ 2-26
Removing Battery Terminal ......................................................................................................................... 2-26
Precautions When Using High-Pressure Grease to Adjust Track Tension .................................................. 2-27
Do Not Disassemble Recoil Spring.............................................................................................................. 2-27
Precaution with High-Pressure Oil ............................................................................................................... 2-27
Handing High-Pressure Hoses .................................................................................................................... 2-27
Waste Material ............................................................................................................................................. 2-28
Maintenance for Air Conditioner .................................................................................................................. 2-28
Compressed Air ........................................................................................................................................... 2-28
Periodic Replacement of Safety Critical Parts ............................................................................................. 2-28

2-3
SAFETY LABELS SAFETY

SAFETY LABELS 0.
The following warning signes and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signes and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.

POSITIONS OF SAFETY PICTOGRAMS 0.

2-4
SAFETY SAFETY LABELS

22

SAFETY LABELS 0.
(1) Precautions for operation, inspection and
32

maintenance (09651-A0641)

Warning!

Read manual before operation, maintaince, disassembly,

assembly and transportation.

(2) Precautions when traveling in reverse

(09802-13000)

Warning
To prevent SEVERE INJURY or DEATH, do the following
before moving machine or its attachments:
Honk horn to alert people nearby.
Be sure no one is on or near the machine.
To prevent SEVERE INJURY or
Use spotter if view is obstructed. DEATH, do the following before
moving machine or its attach-
Follow above even if the machine is equipped with back-up ments
. Honk horn to alert people
alarm and mirrors. nearby.
. Be sure no one is on or near
the machine.
. Use spotter if view is ob-
structed.
Follow above even if the
machine is equipped with
back-up alarm and mirrors.

09802-13000

(3) Precautions for leaving operator's seat

(09654-B0641)

Sign indicates a hazard of unexpected moving of stopped

machine.

Lower working device to ground, move safety lever to lock

position and take engine key with you before leaving
machine.

2-5
SAFETY LABELS SAFETY

(4) Precautions for high-temperature cooling water

(09653-A0481)

Never remove the cap when the engine is at operating

(High) temperature. Stream or high temperature oil blowing
up from the radiator or hydraulic tank, will cause personal
injury and or burns.

Never remove the radiator or hydraulic tank oil filler when

cooling water or hydraulic oil is at high temperatures.

5. Precautions when adjusting track tension

(09657-A0881)

Safety label is attached on the back side of the inspection

cover of the track frame
Plug coming from track shoe tension adjustment device
causing injury.
Read the operation and maintenance manual and carrying
out the correct method when looseing track tension.

(6) Precautions for handling electric wires

(09808-A0881)

There is the hazard to electric shock when handling electric

wires.
Read the operation and maintenance manual and carrying
out the correct method when handling.

(7) Caution for engine running (09667-A0481)

Sign indicates a hazard of rotating parts, such as belt.

Turn off before inspection and maintenance.

2-6
SAFETY SAFETY LABELS

(8) Precautions for handling accumulator

(09659-A057B)

There is the hazard of explotion causing injury.

Do not disassemble the accumulator, make holes in it, weld
it, cut it, hit it, roll it or bring it near flame.

(9) Caution for approach when machine moving

(09806-B1683)

Sign indicates a hazard of being run over by moving equip-

ment.

Keep a safe distance from equipment when it is moving.

(10) ROPS (09620-B2000)

1 2 3
4 5

ROPS CERTIFICATION
This protective structure complies with the standard provided that us properly equipped on the machine which
mass is less than the specified maximum mass.
1. MODEL 3. FOPS LEVEL No. 5. MAX. MASS kg (Lb)

2. MACHINE MODEL 4. SERIAL NO.

WARNING
If some modification is applied to the ROPS. It might not enough strength and might not be complied with the
standard. Consult Komatsu Distributor before altering.
ROPS may provide less protection if it has been structurally damaged or involved roll-over. Consult Komatsu
Distributor in that case.
Always wear seat belt when moving.

2-7
SAFETY LABELS SAFETY

(11) FOPS (09620-C2000)

1 3
2 4

FOPS CERTIFICATION
This protective structure was provided to comply with the following standard.

1. MODEL 2. MACHINE MODEL

3. SERIAL NO. 4. FOPS LEVEL No.

If some modification is applied to the FOBS. It might not enough strength and might not be complied with the
standard. Consult Komatsu Distributor before altering.
FOBS may provide less protection if it has been structurally damaged or involved roll-over. Consult Komatsu
Distributor in that case.
Always wear seat belt when moving.

(12) Precaution for avoiding falling down (09805-C0881)

Sign indicates a hazard of falling
Do not stand on this place here

(13) Jump start prohibited (09842-A0481)

Start the engine only after sitting down in the operator’s
seat.
Do not attempt to start the engine by short-circuiting the
engine starting circuit. Such an act may cause a serious
bodily injury or fire.

2-8
SAFETY GENERAL PRECAUTIONS

GENERAL PRECAUTIONS 0.
SAFETY RULES 0.
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may
be severly impaired putting yourself and everyone else on your jobsite in danger.
When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-
stand all hand signals that are to be used.

IF ABNORMALITIES ARE FOUND 0.

If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been cor-
rected.

CLOTHING AND PERSONAL PROTECTIVE ITEMS 0.

Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other
protruding parts.
If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
Always wear a hard hat and safety shoes. If the nature of
the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
Check that all protective equipment functions properly
before using it.

FIRE EXTINGUISHER AND FIRST AID KIT 0.

Always follow the precautions below to prepare for action if any injury or fire should occur.
Be sure that fire extinguishers have been provided and read
the labels to ensure that you know how to use them in
emergencies.
Carry out periodic inspection and maintenance to ensure
that the fire extinguisher can always be used.
Provide a first aid kit at the storage point. Carry out periodic
checks and add to the contents if necessary.

SAFETY FEATURES 0.
Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if
they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.

KEEP MACHINE CLEAN 0.

If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not
use water or steam to wash the electrical system (sensors, connectors).

2-9
GENERAL PRECAUTIONS SAFETY

If inspection and maintenance is carried out when the

machine is still dirty with mud or oil, there is a hazard that
you will slip and fall, or that dirt or mud will get into your
eyes. Always keep the machine clean.

INSIDE OPERATOR'S COMPARTMENT 0.

When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.
If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
Do not leave parts or tools lying around the operator's compartment.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 0.

Before standing up from the operator's seat, lower the work
equipment completely to the ground, set safety lock lever
and parking lever securely to the LOCK position, then stop
the engine.
If you accidentally touch the levers when they are not Free
locked, there is a hazard that the machine may suddenly
move and cause serious injury or property damage.
Lock
Free
Lock
When leaving the machine, always lower the work equip-
ment completely to the ground, set safety lock lever and
Parking lever securely to the LOCK position, then stop the
engine. Use the key to lock all the equipment. Always
remove the key, take it with you, and keep it in the specified
place.

2-10
SAFETY GENERAL PRECAUTIONS

HANDRAILS AND STEPS 0.

To prevent personal injury caused by slipping or falling off the machine, always do as follows.
Use the parts marked by arrow A in the diagrams when get-
ting on or off the machine.
Never use the parts marked by arrow B when getting on or
off the machine. Use them only when moving along the top
of the track or when checking or carrying out maintenance
inside the side cover, or when filling the tank with oil.
Never jump on or off the machine. In particular, never get on
or off a moving machine. This may cause serious injury.

To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands
and one foot) with the handrails and steps (including the
track shoe) to ensure that you support yourself.
Do not grip the control levers when getting on or off the
machine.
Never climb on the engine hood or covers where there are
no non-slip pads.
Before getting on or off the machine, check the handrails
and steps (including the track shoe). If there is any oil,
grease, or mud on the handrails or steps (including the track
shoe), wipe it off immediately. Always keep these parts
clean. Repair any damage and tighten any loose bolts.
Do not get on or off the machine while holding tools in your hand.

MOUNTING AND DISMOUNTING 0.

Never jump on or off the machine. Never get on or off a moving machine.
If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try
to stop it.

NO PEOPLE ON ATTACHMENTS 0.
Never let anyone ride on the work equipment, or other attachments. There is a hazard of falling and suffering seri-
ous injury.

2-11
GENERAL PRECAUTIONS SAFETY

PREVENTION OF BURNS 0.
Hot coolant
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to
a temperature where it is possible to touch the radiator cap
by hand before starting the operation. Even when the cool-
ant has cooled down, loosen the cap slowly to relieve the
pressure inside the radiator before removing the cap.
Hot oil
To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to at temperature
where it is possible to touch the cap or plug by hand before
starting the operation. Even when the oil has cooled down,
loosen the cap or plug slowly to relieve the internal pres-
sure before removing the cap or plug.

FIRE PREVENTION 0.
Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particu-
larly flammable and can be hazardous. To prevent fire,
always observe the following:
Do not smoke or use any flame near fuel or oil.
Stop the engine before refueling.
Do not leave the machine while adding fuel or oil.
Tighten all fuel and oil caps securely.
Do not spill fuel on overheated surfaces or on parts of
the electrical system.
Use well-ventilated areas for adding or storing oil and
fuel.
Keep oil and fuel in the determined place and do not
allow unauthorized persons to enter.
After adding fuel or oil, wipe up any spilled fuel or oil.
When carrying out grinding or welding work on the chas-
sis, move any flammable materials to a safe place
before starting.
When washing parts with oil, use a non-flammable oil.
Diesel oil and gasoline may catch fire, so do not use
them.
Put greasy rags and other flammable materials into a
safe container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or
tubes that contain flammable liquids.
Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.

Fire coming from electric wiring

Short circuits in the electrical system can cause fire.
Always keep electric wiring connections clean and securely tightened.
Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.

2-12
SAFETY GENERAL PRECAUTIONS

Fire coming from hydraulic line

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the
hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.

Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-
explosion specifications. If such lighting equipment is not used, there is danger of explosion that may cause
serious injury.
When taking the electrical power for the lighting from the machine itself, follow the instructions in this man-
ual.

ACTION IF FIRE OCCURS 0.

If a fire occurs, escape from the machine as follows.
Turn the start switch OFF to stop the engine.
Use the handrails and steps to get off the machine.

WINDOW WASHER LIQUID 0.

Use an ethyl alcohol base washer liquid.
Methyl alcohol base washer liquid may irritate your eyes, so do not use it.

PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 0.

Install ROPS when carrying out operations in places where
there is danger of the machine rolling over or where there is
danger of falling rocks, such as in mines and quarries.
If ROPS is installed, do not remove it when operating the
machine.
ROPS is installed to protect the operator when machine
rolls over. When machine rolls over, ROPS supports its
weight and absorbs its impact energy.
If ROPS is modified, its strength may lower. When modify-
ing it, consult your Komatsu distributor.

If ROPS is deformed by falling objects or by rolling over, its strength lowers and its design functions cannot be
maintained. In this case, be sure to ask your Komatsu distributor about repair method.
Even when the ROPS is installed, if you do not fasten your seat belt securely, it cannot protect you properly.
Always fasten your seat belt when operating the machine.

PRECAUTIONS FOR ATTACHMENTS 0.

When installing optional parts or attachments, there may be problems with safety or legal restrictions. There-
fore contact your Komatsu distributor for advice.
Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.

CAB WINDOW GLASSES 0.

If the cab glass on the work equipment side is broken, there is a hazard that the work equipment may contact the
operator's body directly. Stop operation immediately and replace the glass.

UNAUTHORIZED MODIFICATION 0.
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.

2-13
GENERAL PRECAUTIONS SAFETY

SAFETY AT WORKSITE 0.
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there
is a hazard of fire, so be careful when operating.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not carry out operations at places where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may
be buried under the worksite, contact each utility and iden-
tify their locations. Be careful not to sever or damage any of
these lines.
Take necessary measures to prevent any unauthorized per-
son from entering the operating area.
In particular, if you need to operate on a road, protect
pedestrian and cars by designating a person for worksite
traffic duty or by installing fences around the worksite.
When traveling or operating in shallow water or on soft
ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting
operations.

WORKING ON LOOSE GROUND 0.

Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 0.

Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause
serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as
follows.
Before starting work near electric cables, inform the local power company of the work to be performed, and ask
them to take the necessary action.
Even going close to high-voltage cables can cause electric
shock, which may cause serious burns or even death. Voltage of Cables Safety Distance
Always maintain a safe distance (see the table on the right)
between the machine and the electric cable. Check with the 100 V - 200 V Over 2 m
local power company about safe operating procedure
before starting operations. 6,600 V Over 2 m
To prepare for any possible emergencies, wear rubber 22,000 V Over 3 m
shoes and gloves. Lay a rubber sheet on top of the seat,
and be careful not to touch the chassis with any exposed 66,000 V Over 4 m
part of your body.
Use a signalman to give warning if the machine approaches 154,000 V Over 5 m
too close to the electric cables. 187,000 V Over 6 m
When carrying out operations near high voltage cables, do
not let anyone come close to the machine. 275,000 V Over 7 m
If the machine should come too close or touch the electric
cable, to prevent electric shock, the operator should not 500,000 V Over 11 m
leave the operator's compartment until it has been con-
firmed that the electricity has been shut off.
Also, do not let anyone come close to the machine.

2-14
SAFETY GENERAL PRECAUTIONS

ENSURE GOOD VISIBILITY 0.

Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to
ensure that operations and travel can be carried out safely. Always do as follows.
Position a signalman if there are areas at the rear of the machine where the visibility is not good.
When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.

VENTILATION FOR ENCLOSED AREAS 0.

Exhaust fumes from the engine can kill.
If it is necessary to start the engine within an enclosed area,
or when handling fuel, flushing oil, or paint, open the doors
and windows to ensure that adequate ventilation is provided
to prevent gas poisoning.

CHECKING SIGNALMAN'S SIGNALS AND SIGNS 0.

Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.

BE CAREFUL ABOUT ASBESTOS DUST 0.

Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsites
handling demolition work or work handling industrial waste.
Always observe the following.
Spray water to keep down the dust when cleaning. Do not
use compressed air for cleaning.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position. All
workers should use an approved respirator.
Do not allow other persons to approach during the opera-
tion.
Always observe the rules and regulations for the work site
and environmental standards.
This machine does not use asbestos, but there is a danger that
imitation parts may contain asbestos, so always use genuine
Komatsu parts.

2-15
PRECAUTIONS FOR OPERATION SAFETY

PRECAUTIONS FOR OPERATION 0.

BEFORE STARTING ENGINE 0.
If there is a warning tag hanging from the work equipment con-
trol lever, do not start the engine or touch the levers .

CHECKS BEFORE STARTING ENGINE 0.

Carry out the following checks before starting the engine at the beginning of the day's work.
Completely remove all flammable materials accumulated around the engine and battery, and remove any dirt
from the windows, mirrors, handrails and steps.
Remove all dirt from the surface of the lens of the front lamps and working lamps, and check that they light up
correctly.
Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and
check for damage to the electric wiring.
Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no dam-
age or wear to the seat belt or mounting clamps.
Check that the gauges work properly, check the angle of the lights and working lamps, and check that the con-
trol levers are all at the neutral position.
When starting the engine, check that the parking lever and safety lock lever are at the LOCK position.
Adjust the mirrors so that you can get a good rear-view from the operator's seat.
For the details of adjustment, see “ADJUST MIRROR ( 3-66 )“.
Check that there are no persons or obstacles above, below, or in the area around the machine.

PRECAUTIONS WHEN STARTING 0.

Start and operate the machine only while seated.
Do not attempt to start the engine by short-circuiting the
engine starting circuit. Such an act may cause a serious
bodily injury or fire.
When starting the engine, sound the horn as a warning.
Do not allow anyone apart from the operator to ride on the
machine.

2-16
SAFETY PRECAUTIONS FOR OPERATION

PRECAUTIONS IN COLD AREAS 0.

Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery and cause the battery to explode.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.

OPERATION 0.
CHECKS BEFORE OPERATION 0.
When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
Always fasten your seat belt.
Check the operation of travel, steering and brake systems,
and work equipment control system.
Check for any abnormality in the sound of the machine,
vibration, heat, smell, or gauges; check also that there is no
leakage of oil or fuel.
If any abnormality is found, carry out repairs immediately.

PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE 0.

Before travelling, check again that there is no one in the sur-
rounding area, and that there are no obstacles.
Before travelling, sound the horn to warn people in the area.
Always operate the machine only when seated.
Do not allow anyone apart from the operator to ride on the
machine.
Check that the back-up alarm (alarm buzzer when machine
travels in reverse) works properly.
Always lock the door and windows of the operator's com-
partment in position (open or closed).
On jobsites where there is a hazard of flying objects or of
objects entering the operator's compartment, check that the
door and windows are securely closed.
If there is an area to the rear of the machine where the visi-
bility is obstructed, use a flagman. Be extremely careful not
to hit anything and drive the machine slowly.
Always be sure to carry out the above precautions even when the machine is equipped with mirrors.

2-17
PRECAUTIONS FOR OPERATION SAFETY

PRECAUTIONS WHEN TRAVELING 0.

Never turn the starting switch to the OFF position when traveling. It is dangerous if the engine stops when the
machine is traveling. When the engine is off, it is impossible to operate the steering. Apply the brakes and stop
the machine immediately, if the engine stops.
When traveling on flat ground, keep the work equipment 40 to 50 cm high above the ground.
When traveling on rough ground, travel at low speed and do
not operate the steering suddenly. There is danger that the
machine may turn over. The work equipment may hit the
ground surface and cause the machine to lose its balance,
or may damage the machine or structures in the area.

Avoid traveling over obstacles when possible. If the

machine has to travel over an obstacle, keep the work
equipment close to the ground and travel at low speed.
Never travel over obstacles which make the machine tilt
strongly to one side.
When traveling or carrying out operations, always keep a
safe distance from people, structures, or other machines to
avoid coming into contact with them.
When passing over bridges or structures, check first that the
structure is strong enough to support the weight of the
machine. When traveling on public roads, check first with
the relevant authorities and follow their instructions.
When operating in tunnels, under bridges, under electric wires, or other places where the height is limited,
operate slowly and be extremely careful not to let the work equipment hit anything.
Do not approach the edge of a cliff carelessly. When dropping soil over a cliff for banking or reclamation, leave
soil of one scoop at the edge of the cliff and push it with the next scoop.
When the machine passes over the top of a hill or when a load is dumped over a cliff, the load is suddenly
reduced, and there is danger that the travel speed rises suddenly. To prevent this, lower the travel speed.
If the machine moves with only either side of the blade loaded, its tail may swing. Take care.

TRAVELING ON SLOPES 0.
To prevent the machine from tipping over or slipping to the side, always do as follows.
When traveling on slops, keep the blade approxmately 20 to
30 cm above the ground. In case of emergency, quickly
lower the blade to the ground to help the machine to stop.
Apply the brake and use the engine as a brake, if neces-
sary.
Always travel straight up or down a slope. Traveling at an
angle or across the slope is extremely dangerous.
Do not turn on slopes or travel across slopes. Always go
down to a flat place to change the position of the machine,
then travel on to the slope again.
Travel on grass, fallen leaves, or wet steel plates with low
speed. Even with slight slopes there is a hazard that the
machine may slip.
When driving down a slope, never shift gear or place the transmission in neutral. The engine brake cannot be
used and this creates a dangerous condition. Always travel downhill in the same speed range as when travel-
ing uphill.
When turning on a downhill ground, lower the travel speed.

2-18
SAFETY PRECAUTIONS FOR OPERATION

PROHIBITED OPERATIONS 0.
To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff
with the sprocket at the rear when carrying out operations.
When operating the machine, take care that it will not exceed its performance values such as stability, maxi-
mum using load, etc. to prevent rolling of the machine caused by an overload and disasters caused by break-
age of the work equipment.

USING BRAKES 0.
When the machine is traveling, do not rest your foot on the brake pedal. If you travel with your foot resting on
the pedal, the brake will always be applied, and this will cause the brakes to overheat and fail.
Do not depress the brake pedal repeatedly if not necessary. If this is neglected, the brake will be overheated
and will not work when required.
When traveling downhill, use the braking force of the engine.

OPERATE CAREFULLY ON SNOW 0.

Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the
machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be par-
ticularly careful when working on slopes.
With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful
not to leave the road shoulder or to get trapped in a snow drift.
When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out opera-
tions carefully.
When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and use the
engine as a brake while appling the foot brake intermittently (depress the brake intermittently several times). If
necessary, lower the blade to the ground to stop the machine.

PARKING MACHINE 0.
Park the machine on level ground where there is no danger
of falling rocks or landslides, or of flooding if the land is low,
and lower the work equipment to the ground.
If it is necessary to park the machine on a slope, set the
blocks under the tracks to prevent the machine from mov-
ing, then dig the work equipment into the ground.

Thrust the edge

Block
Thrust the edge
When leaving the machine, set the safety lock lever and
parking lever to the LOCK position, stop the engine, and
use the key to lock all the equipment. Always remove the
key and take it with you.
Work equipment posture: See “PARKING MACHINE ( 3-89 )“.
Locks: See “LOCKING ( 3-91 )“ Free
Always close the door of the operator's compartment.
Lock
Free
Lock

2-19
PRECAUTIONS FOR OPERATION SAFETY

TRANSPORTATION 0.
The machine can be divided into parts for transportation, so when transportating the machine, please contact your
Komatsu distributor to have the work carried out.

SHIPPING 0.
When shipping the machine on a trailer, do as follows.
The weight, transportation height, and overall length of the machine differ according to the work equipment, so
be sure to confirm the dimensions.
When passing over bridges or structures on private land, check first that the structure is strong enough to sup-
port the weight of the machine. When traveling on public roads, check first with the relevant authorities and fol-
low their instructions.
For details of the shipping procedure, see “TRANSPORTATION ( 3-100 )“ in the OPERATION section.

BATTERY 0.
BATTERY HAZARD PREVENTION 0.
Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.
Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.
When the battery electrolyte is below LOWER LEVEL, don't either use or charge the battery. Otherwise, that
may cause explosion. Always carry out periodic checks of the battery electrolyte, and add distilled water up to
UPPER LEVEL.
For the method of checking the battery electrolyte, see CHECK LEVEL OF BATTERY ELECTROLYTE ( 4-41 ).
When working with batteries, always wear safety glasses and rubber gloves.
Never smoke or use any flame near the battery.

If you spill acid on your clothes or skin, immediately flush

the area with large amount of water.
If acid gets into your eyes, flush them immediately with
large amount of water and seek medical attention.

Before working with batteries, turn the starting switch to the OFF position.

As there is a hazard that sparks will be generated, always do as follows.

Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals
securely.
Tighten the battery terminals securely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
Tighten the battery caps securely.
Install the battery securely to the determined place.

2-20
SAFETY PRECAUTIONS FOR OPERATION

STARTING WITH BOOSTER CABLE 0.

If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
When starting with a booster cable, carry out the starting
operation with two workers (one worker sitting in the opera-
tor's seat and the other working with the battery).
When starting from another machine, do not allow the two
machines to touch.
When connecting the booster cables, turn the starting
switch OFF for both the normal machine and problem
machine. There is a hazard that the machine will move
when the power is connected.
Be sure to connect the positive (+) cable first when installing
the booster cables. Disconnect the negative (-) cable
(ground side) first when removing them.
When removing the booster cables, be careful not to let the
booster cable clips touch each other or to let the clips touch
the machine.
Always wear safety goggles and rubber gloves when start-
ing the engine with booster cables.
When connecting a normal machine to a problem machine
with booster cables, always use a normal machine with the
same battery voltage as the problem machine.
For the procedure of starting the engine with booster
cables, see STARTING ENGINE WITH BOOSTER CABLE
( 3-109 ).

2-21
PRECAUTIONS FOR OPERATION SAFETY

TOWING 0.
WHEN TOWING 0.
Injury or death could result if a disabled machine is towed
incorrectly. Always observe the following rules.
Never use a towing method different from the one described
in this manual.
For the method of towing, see METHOD OF TOWING
MACHINE ( 3-108 ).
When handling a wire rope, always wear leather gloves.
When working with others to prepare for towing, signals
should be agreed upon beforehand.
If your machine is towed by another machine, stop the
engine and release the brake. Please contact your Komatsu
distributor to have the brake released.
If this machine cannot travel under its own power, release
the brakes, then tow the machine with another machine.
Please contact your Komatsu distributor to have the brakes
released.
Towing on slopes is dangerous. When doing so, choose a
gentle slope. If no gentle slope is available, make such a
slope by earth-removal work.
When connecting up a towing machine, do not let anyone
enter the area between the towing machine and the equip-
ment being towed.
Do not straddle the towing cable or wire rope.
When your machine is towed by another machine, ALWAYS
use a wire rope with a sufficient towing capacity.
Set the towing machine and the towing connection of the
equipment being towed in a straight line when connecting it.
Take up the slack in the wire rope and tow the machine.
When lifting the machine up, use the towing hook.
If the machine is stuck in sandy soil, dig out the soil around
the towing hook, then use the towing hook to pull the
machine out.
Permissible load for towing hook: 21,800 kg (213,780 N).
Do not use a broken (A), kinked (B) or frayed (C) wire rope.

2-22
SAFETY PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS FOR MAINTENANCE 0.

WARNING TAG 0.
When carrying out inspection or maintenance, ALWAYS
attach the “DO NOT OPERATE“ warning tag to the blade
control lever in the operator's cab to alert others that you
are working on the machine. Attach additional warning tags
around the machine in necessary.

Warning tag Part No. 09963-A1640

This tag is placed in the same case as is this operation and
maintenace manual.
If others start the engine, or touch or operate the work
equipment control lever while you are performing service or
maintenance, you could suffer serious injury or property
damage.

KEEP WORK PLACE CLEAN AND TIDY 0.

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out opera-
tions safely.
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure your-
self.

APPOINT LEADER WHEN WORKING WITH OTHERS 0.

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow
his instructions during the operation.

2-23
PRECAUTIONS FOR MAINTENANCE SAFETY

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 0.

Stop the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground and
stop the engine.
After stopping the engine, operate the work equipment con-
trol lever to the RAISE and LOWER positions 2 or 3 times to
release the pressure remaining in the hydraulic circuit, then
set the safety lock lever and Parking lever to LOCK position.

Free

Lock
Free
Lock
Put blocks under the track to prevent the machine from
moving.

Block

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 0.

To prevent injury, do not carry out maintenance with the engine
running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and
do as follows.
One worker must always sit in the operator's seat and be
ready to stop the engine at any time. All workers must
maintain contact with the other workers.
Place the parking lever and safety lock lever at the LOCK
position to prevent the work equipment from moving.
When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts,
so be careful not to come close.
Do not touch any control levers. If any control lever must be
operated, give a signal to the other workers to warn them to
move to a safe place.
Never drop or insert tools or other objects into the fan or fan
belt. Parts may break or be sent flying. Free

Lock

Free
Lock

2-24
SAFETY PRECAUTIONS FOR MAINTENANCE

PROPER TOOLS 0.
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.

HANDLING ACCUMULATOR 0.
On machines equipped with an accumulator, for a short time after the engine is stopped, if the blade 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 and Parking lever in the LOCK position.
When releasing the pressure inside the work equipment circuit on machines equipped with an accumulator, fol-
low the procedure given in the following section.
Method of releasing pressure : See “ACCUMULATOR, HANDLING ( 3-54 )“.
The accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless procedure may
cause an explosion which could lead to serious injury or prop-
erty damage. For this reason, always observe the following
precautions.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it, weld it, or use a cutting torch.
Do not hit or roll the accumulator, or subject it to any impact.
When disposing of the accumulator, the gas must be
released. Please contact your Komatsu distributor to have
this work performed.

PERSONNAL 0.
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the
area. If necessary, employ an observer.

ATTACHMENTS 0.
Appoint a leader before starting removal or installation oper-
ations for attachments.
Place attachments that have been removed from the
machine in a stable condition so that they do not fall. And
take steps to prevent unauthorized persons from entering
the storage area.

2-25
PRECAUTIONS FOR MAINTENANCE SAFETY

WORK UNDER THE MACHINE 0.

If it is necessary to go under the work equipment or the
machine to carry out service and maintenance, support the
work equipment and machine securely with blocks and
stands strong enough to support the weight of the work
equipment and machine.
It is extremely dangerous to work under the machine if the
track shoes are lifted off the ground and the machine is sup-
ported only with the work equipment. If any of the control
levers is touched by accident, or there is damage occurring
to the hydraulic piping, the work equipment or the machine
will suddenly drop. This is extremely dangerous. Never
work under the work equipment or the machine.

NOISE 0.
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov-
ers or ear plugs while working.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.

PRECAUTIONS WHEN USING HAMMER 0.

When using a hammer, pins may fly out or metal particles may
be scattered. This may lead to serious injury. Always do as
follows.
If hard metal parts such as pins, bucket teeth, cutting edges,
or bearings are hit with a hammer, there is a hazard that
pieces might be scattered and cause injury. Always wear
safety goggles and gloves.
When hitting pins or bucket teeth, there is a hazard that bro-
ken pieces might be sent flying and injure people in the sur-
rounding area. Always check that there is no one in the
surrounding area.
There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.

REPAIR WELDING 0.
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.

REMOVING BATTERY TERMINAL 0.

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of
the battery to prevent the flow of current.

2-26
SAFETY PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION 0.

Grease is pumped into the track tension adjustment system
under high pressure. If the specified procedure for mainte-
nance is not followed when making adjustment, grease
drain valve (1) may fly out and cause serious injury or dam-
age.
When loosening grease drain valve (1) to loosen track ten-
sion, never loosen it more than one turn. In doing so, loosen
the valve slowly.
Never put your face, hands, feet, or any other part of your
body directly in front of grease drain valve (1).

DO NOT DISASSEMBLE RECOIL SPRING 0.

Never attempt to disassemble the recoils spring assembly. It contains a spring under high pressure which serves
as a shock absorber for the idler. If it is disassembled by mistake, the spring will fly out and cause serious injury.
When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work.

PRECAUTION WITH HIGH-PRESSURE OIL 0.

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury, so always do as follows.
Do not carry out inspection or replacement work when the hydraulic system is under pressure.
If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the pip-
ing and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly. If you are hit by a jet of high-pres-
sure oil and suffer injury to your skin or eyes, wash the
place with clean water, and consult a doctor immediately for
medical attention.

PRECAUTION FOR HIGH FUEL PRESSURE 0.

When the engine is running, high-pressure is generated in the engine fuel piping. When carrying out inspection or
maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the internal pres-
sure to go down before starting the operation.

HANDLING HIGH-PRESSURE HOSES 0.

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are
found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.

2-27
PRECAUTIONS FOR MAINTENANCE SAFETY

Damaged or leaking hydraulic fitting.

Frayed or cut covering or exposed reinforcement wire layer.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.

PRECAUTION FOR HIGH VOLTAGE 0.

When the engine is running and immediately after it is stopped, high voltage is generated inside the engine
controller and the engine injector, and there is danger of electrocution. Never touch the inside of the controller
or the engine injector portion.
If it is necessary to touch the inside of the controller or the engine injector portion, please contact your Komatsu
distributor.

WASTE MATERIAL 0.
To prevent pollution, pay careful attention to the method of disposing of waste materials.
Always put oil drained from your machine in containers.
Never drain oil directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.

MAINTENANCE FOR AIR CONDITIONER 0.

If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frost-
bite.
Never touch refrigerant.

COMPRESSED AIR 0.
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 0.

To enable the machine to be used safely for long periods, always periodically add oil and carry out inspection
and maintenance. However, to further increase safety, periodically replace the seat belt, hoses, and other parts
which have a close relationship to safety.
See Replacing critical parts: PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ( 4-14 )
The material of these components naturally changes over time, and repeated use causes deterioration, wear,
and fatigue. As a result, there is a hazard that these components may fail and cause serious injury or death. It
is difficult to judge the remaining life of these components from external inspection or the feeling when operat-
ing, so always replace them at the specified interval.
Replace or repair safety-critical parts if any defect is found, even when they have not reached the time speci-
fied interval.

2-28
 OPERATION
43

WARNING
Please read and make sure that you understand the safety
volume before reading this section.
GENERAL VIEW OPERATION

GENERAL VIEW 0.
GENERAL VIEW OF MACHINE 0.

(1) Blade (6) Sprocket

(2) Blade lift cylinder (7) Track frame

(3) Cab (8) Frame

(4) ROPS (9) Track shoe

(5) Ripper

3-2
OPERATION GENERAL VIEW

GENERAL VIEW OF CONTROLS AND GAUGES 0.

(1) Parking lever (12) Fan selector switch

(2) Safety lock lever (13) Starting switch

(3) Cigarette lighter (14) Information switch

(4) Fuel control dial (15) Buzzer cancel switch

(5) Joystick (Steering, directional and gear shift lever) (16) Brake pedal

(6) Auto shift down switch (17) Deceleration pedal

(7) Preset mode switch (18) Blade control lever

(8) Head lamp switch (19) Horn switch

(9) Air conditioner panel or heater panel (20) Ripper control lever

(10) Display panel A (Speed range, Engine speed) (21) Wiper switch

(11) Rear lamp switch (22) Room lamp switch

3-3
GENERAL VIEW OPERATION

FRONT PANEL

(1) Engine cooling water temperature gauge (10) Hydraulic oil temperature caution lamp

(2) Power train oil temperature gauge (11) Engine preheating pilot lamp

(3) Hydraulic oil temperature gauge (12) Maintenance caution lamp

(4) Fuel gauge (13) Warning lamp

(5) Radiator coolant level caution lamp (14) Filter, oil change interval lamp

(6) Charge caution lamp (15) Display panel A (Speed range, Engine speed)

(7) Engine oil pressure caution lamp (16) Display panel B (Multi-information)

(8) Engine cooling water temperature caution lamp (17) Fan reverse rotation lamp

(9) Power train oil temperature caution lamp

3-4
OPERATION EXPLANATION OF COMPONENTS

EXPLANATION OF COMPONENTS 0.
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.

FRONT PANEL 0.

A: Check monitor group D: Meter group

B: Caution monitor group E: Switch

C: Emergency caution group F: Lamp

A: Basic check items (see CHECK MONITOR GROUP ( 3-7 ))

Before the engine is started, the basic items among the check before starting items that must be checked are dis-
played.
If there is any abnormality, the caution lamp for the location of the abnormality flashes.

NOTICE
When carrying out the check before starting, do not rely only on these monitors. Always carry out the
inspection items according to the Maintenance section or Section OPERATION ( 3-55 ).
B: CAUTION MONITOR GROUP (see “CAUTION MONITOR GROUP ( 3-8 )“)

CAUTION
If these caution lamp flash, check and repair the appropriate location as soon as possible.

These are items, which need to be observed while the engine is running. If any abnormality occurs, items, which
need to be repaired as soon as possible, are displayed.
If there is any abnormality, the appropriate monitor lamp will flash to indicate the location of the abnormality.

3-5
EXPLANATION OF COMPONENTS OPERATION

C: EMERGENCY CAUTION ITEMS (See “EMERGENCY CAUTION ITEMS ( 3-10 )“)

CAUTION
If the caution lamp for any of these items flashes, stop the engine immediately or run it at low idling, and
take the following action.

This displays those of the abnormality items for which action must be taken immediately when the engine is run-
ning.
If there is any abnormality, the monitor showing the location of the abnormality will flash and the alarm buzzer will
sound.

D: Meter display portion (see “METER GROUP ( 3-12 )“)

This consists of the preheating pilot lamp, power train oil temperature gauge, engine water temperature gauge,
hydraulic oil temperature gauge. fuel gauge, dual/single selector display lamp, display panel A (speed range dis-
play, engine speed) and display panel B (multi-information).

E: Switches (for details, see “SWITCH ( 3-28 )“.)

These consist of the starting switch, buzzer cancel switch, front lamp switch, rear lamp switch, auto shift down
switch, Preset mode switch, information switch, and Fan selector switch.

F: Lamps (for details, see “LAMP ( 3-19 )“.)

These consist of the warning lamp and filter, oil change interval lamp and Fan reverse rotation lamp.

3-6
OPERATION EXPLANATION OF COMPONENTS

CHECK MONITOR GROUP 0.

NOTICE
When carrying out checks before starting, do not simply rely on the monitor. Always refer to OPERA-
TION ( 3-55 ) to carry out the checks.
Park the machine on level ground and then check the monitor lamps.
Confirm that the monitor lamp lights up for about 2 seconds after the starting switch is turned to ON. If
any lamp does not light up, please contact your Komatsu distributor to inspect it.

REMARK
When the starting switch is turned ON before starting the engine, the caution lamp flash for 2 seconds,
the warning lamp lights up for 2 seconds, and the alarm buzzer sounds for 2 second.
The caution lamps cannot be checked for breakage until at least 5 seconds after the engine has been
stopped.

This displays the basic items among the check before starting items that must be checked before starting the
engine. If there is any abnormality, the caution lamp for the location of the abnormality will flash.

A (1) Radiator coolant level monitor

RADIATOR COOLANT LEVEL MONITOR 0.

This lamp (1) warns the operator that the level of the cooling
water in the radiator has gone down.
If the lamp flashes, check the level of the cooling water in the
main radiator, and add water.

3-7
EXPLANATION OF COMPONENTS OPERATION

CAUTION MONITOR GROUP 0.

CAUTION
If these caution lamps item flash, check and repair the appropriate location as soon as possible.

NOTICE
Park the machine on level ground and check the monitor lamps.
Confirm that these monitor lamps light for about 2 seconds after the starting switch is turned to ON. If
any monitor lamp does not light, ask your Komatsu distributor to inspect it.

These are items, which need to be observed when the engine is running. If any abnormality occurs, the item need-
ing immediate repair is displayed. If there is any abnormality, the abnormal location on the caution lamp will flash.

B (1) Charge level monitor B (2) Maintenance caution lamp

CHARGE MONITOR 0.
This lamp (1) indicates an abnormality in the charging system
while the engine is running.
If the monitor lamp flashes, check the V-belt tension. If any
abnormality is found, see “OTHER TROUBLE ( 3-112 )“.

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 indi-
cate an abnormality.

3-8
OPERATION EXPLANATION OF COMPONENTS

MAINTENANCE CAUTION LAMP 0.

This monitor (2) flashes when the filter or oil change interval
has been reached. SWITCH DISPLAY PANEL B (Multi-infor-
mation) ( 3-14 ) to the maintenance mode and check or replace
the applicable filter or oil.

3-9
EXPLANATION OF COMPONENTS OPERATION

EMERGENCY CAUTION ITEMS 0.

CAUTION
If the caution lamp for any of these items flashes, stop the engine immediately or run it at low idling, and
take the following action.

NOTICE
Park the machine on level ground and check the monitor lamps.
Confirm that these caution lamps light for about 2 seconds after the starting switch is turned to ON. If
any monitor lamp does not light, ask your Komatsu distributor to inspect it.

These items need to be observed while the engine is running. If any abnormality occurs, items that need to be
repaired immediately are displayed.
If there is any abnormality, alarm buzzer sounds intermittently and the abnormal location on the caution lamp will
flash.

C (1) Engine oil pressure caution lamp C (2) Engine cooling water temperature caution lamp

C (3) Power train oil temperature caution lamp C (4) Hydraulic oil temperature caution lamp
ENGINE OIL PRESSURE CAUTION LAMP 0.
This lamp (1) indicates a low engine oil pressure.
If the monitor lamp flashes, stop the engine and check it imme-
diately.

REMARK
The alarm buzzer sounds, when the starting switch is
turned to ON immediately after the engine oil changed. It
does not indicate an abnormality.

3-10
OPERATION EXPLANATION OF COMPONENTS

ENGINE COOLING WATER TEMPERATURE MONITOR 0.

This lamp (2) 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.

POWER TRAIN OIL TEMPERATURE MONITOR 0.

This lamp (3) indicates a rise in the oil temperature of the
torque converter outlet.
When the monitor lamp flashes, run the engine at the low idling
speed until the green range of the power train oil temperature
gauge lights.

HYDRAULIC OIL TEMPERATURE MONITOR 0.

This lamp (4) indicates a rise in the hydraulic oil temperature.
When the monitor lamp flashes, stop the machine and run the
engine at the low idling speed until oil temperature falls.

3-11
EXPLANATION OF COMPONENTS OPERATION

METER GROUP 0.
NOTICE
While the engine is at rest, turn the starting switch ON to see if engine cooling water temperature gauge,
power train oil temperature gauge, fuel gauge and monitor lamps all light up.
If they do not, ask your Komatsu distributor to inspect it.

D (1) Engine cooling water temperature gauge D (6) Engine preheating pilot lamp

D (2) Power train oil temperature gauge D (7) Display panel A (Speed range display)

D (3) Hydraulic oil temperature gauge D (7) Display panel B (multi-information)

D (4) Fuel gauge

ENGINE COOLING WATER TEMPERATURE GAUGE 0.
This gauge (1) indicates the temperature of the cooling water.
If the temperature is normal during operation, the green range
(B) will light.
If the red range (C) lights up during operation, move the Fuel
control dial to lower the engine speed to approx. 3/4 of the full
speed, and run until the water temperature enters the green
range (B).
During operation, if red range (C) lights up, the engine water
temperature monitor flashes, and the alarm buzzer sounds,
stop the machine, run the engine at low idling, and wait for the
water temperature to go down to green range (B) .
(A): White range
(B): Green range
(C): Red range
NOTICE
If the water temperature gauge often enters the red range (C), check the radiator for clogging.

3-12
OPERATION EXPLANATION OF COMPONENTS

POWER TRAIN OIL TEMPERATURE GAUGE 0.

This gauge (2) indicates the oil temperature of the torque con-
verter outlet. If the temperature is normal during operation, the
green range will light.
If the red range (C) lights up during operation, move the fuel
control lever to lower the engine speed to approx. 3/4 of the full
speed, reduce the load and run until the oil temperature enters
the green range (B).
If the power train oil temperature enters the red range (C) , and
the power train oil temperature caution lamp flashes and the
alarm buzzer sounds, stop the machine and run at low idling
until the oil temperature enters the green range (B) .
(A): White range
(B): Green range
(C): Red range

NOTICE
If the power train oil temperature gauge often enters the
red range (C), we recommend you to lower the travel
speed one range (for example, F2 → F1) to reduce the load
on the power train when operating.

HYDRAULIC OIL TEMPERATURE GAUGE 0.

This gauge (3) indicates the oil temperature of the hydraulic oil.
If the temperature is normal during operation, the green range
(B) will light.
If the red range (C) lights up during operation, move the fuel
control lever to lower the engine speed to approx. 3/4 of the full
speed, reduce the load and run until the oil temperature enters
the green range (B).
(A): White range
(B): Green range
(C): Red range

FUEL LEVEL GAUGE 0.

This meter (4) shows the level of fuel in the fuel tank.
During normal operation, the green range (B) should be lighted
up.
If the red range (A) lights up during operation, add fuel immedi-
ately. If this is not done, the engine speed will become irregular
or an error display will be shown on the monitor.
(A): Red range
(B): Green range

REMARK
The display is not proportional to the amount of fuel
remaining.
If only the red range (A) lights up, there is less than 60
liters of fuel remaining.

3-13
EXPLANATION OF COMPONENTS OPERATION

ENGINE PREHEATING PILOT LAMP 0.

This lamp (5) indicates that the engine is being preheated by
the electrical heater during cold weather.
The engine controller detects the water temperature and auto-
matically actuates the preheating in low temperatures when
starting the engine.

DISPLAY PANEL A (speed range display, engine speed) 0.

Meter (6) displays the transmission speed range being used on
the machine and engine speed. Engine speed Speed range
When the transmission is in 1st FORWARD, the display
shows F1, and when it is in 1st REVERSE, the display
shows R1.
The peripheral bar graph indicates the engine speed. When
the red range lights up during running, shift the gear to a
lower speed to run the engine at a speed within the green
range. Red

SWITCH DISPLAY PANEL B (Multi-information) 0.

This monitor (7) displays information related to the condition of
the machine on the top and bottom lines of the display portion.
The content of the display can be switched by operating the
Information switch and Buzzer cancel switch.

(1) Operating mode (normal operation screen)

Use this mode when operating the machine.

REMARK
When the starting switch is turned from the OFF position
to the ON position, the multi-information is set to the oper-
ating mode.

The shift mode selected by operation of the GEARSHIFTING OPERATION USING PRESET MODE FUNCTION (
3-83 ) through the shift mode selection is displayed on the left side of the monitor.
The total operating hours of the machine is displayed at the bottom right of the monitor. (Use the service meter
function display to set the interval for periodic maintenance.)
When the engine is running, the service meter advances, even if the machine is not being used.
When the engine is running, the hourglass mark pilot display at the side of the meter lights up to show that the
meter is advancing.
The meter advances by 1 for every hour of operation, regardless of the engine speed.
If there is a failure in the machine, the failure code is also displayed on the top line. If a failure code is displayed,
carry out the remedy given in “OTHER TROUBLE ( 3-112 )“.

3-14
OPERATION EXPLANATION OF COMPONENTS

(2) Maintenance mode

The maintenance mode is displayed by continuing to turn the

information switch in the direction for 2.5 seconds.
For details, see “METHOD OF USING DISPLAY PANEL B
(Multi-information) ( 3-21 )“.

3-15
EXPLANATION OF COMPONENTS OPERATION

SWITCH 0.

E (1) Starting switch E (5) Rear lamp switch

E (2) Buzzer cancel switch E (6) Fan selector switch

E (3) Preset mode switch E (7) Information switch

E (4) Head lamp switch E (8) Auto shift down switch

STARTING SWITCH 0.
This switch (1) is used to start the engine.

OFF
Key insertion-withdrawal position. None of electrical circuits
activate.

ON
Charging and electric device circuits activate. Keep key at ON
after starting.

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.

3-16
OPERATION EXPLANATION OF COMPONENTS

BUZZER CANCEL SWITCH 0.

When this switch (2) is operated to the left or right, the alarm
buzzer stops.
When the information monitor is in the maintenance mode, this
switch can be operated to move the cursor to the left or right.
(a) position: Cancel
(c) position: Select

PRESET MODE SWITCH 0.

Turn the switch (3) to the right to set the desired transmission
speed range before starting (F1-R1,F1-R2,F2-R2) .
Position (a) : Manual mode
Position (b) : Preset mode

FRONT LAMP SWITCH 0.

This switch (4) lights up when the front lamp, left and right
working lamps on the front fender, and panel lamp light up.
(a) OFF position: Goes out
(b) ON position: Lights up

REAR LAMP SWITCH 0.

This switch (5) lights up when the rear lamp and panel lamp
light up.
(a) OFF position: Lamps are out
(b) ON position: Lamps light up

3-17
EXPLANATION OF COMPONENTS OPERATION

FAN ROTATION SELECTOR SWITCH 0.

Use this switch (6) to switch the fan to reverse or cleaning
mode.
Position (a): Normal mode
Position (b): Reverse mode
Position (c): Cleaning mode

Use the reverse mode to maintain the temperature in cold

areas. Use the cleaning mode to remove dirt when cleaning
the radiator.
In the cleaning mode, the fan always rotates at 100% speed.
Always stop the engine before operating the fan selector
switch.
If the fan selector switch is operated when the engine is run-
ning, the fan operation confirmation lamp will flash to indicate
that it is impossible to operate the switch.

INFORMATION SWITCH 0.
This switch (7) is used to carry out the switching of the informa-
tion monitor display mode and the switching of the cursor with
the maintenance mode.
(a) position: Cursor moves to left
(c) position: Cursor moves to right

AUTO SHIFT DOWN SWITCH 0.

When this switch (8) is operated to the right, if the travel speed
drops because of the load conditions when traveling, the trans-
mission automatically shifts to low speed.
(a) OFF position: Automatic operation canceled
(b) ON position: Automatically shifts down to low speed

For details, see “AUTO SHIFT DOWN OPERATION ( 3-84 )“.

3-18
OPERATION EXPLANATION OF COMPONENTS

LAMP 0.

F (1) Warning lamp F (3) Fan reverse rotation lamp

F (2) Filter, oil change interval lamp

WARNING LAMP 0.
NOTICE
If the alarm buzzer sounds, stop work immediately and
carry out inspection and maintenance of the appropriate
point.

When the caution lamp for the B CAUTION and C CAUTION

groups on the machine monitor system flashes, and an abnor-
mality has occurred in the electronic control system, this lamp
(1) also flashes at the same time.
If the lamp flashes, check the monitor panel to locate the
abnormality.
When the monitor inside the C CAUTION group flashes, the
alarm buzzer also sounds continuously.

3-19
EXPLANATION OF COMPONENTS OPERATION

FILTER, OIL CHANGE INTERVAL LAMP 0.

This lamp lights up when it comes near the time for replacing
the filter or oil.

FAN OPERATION CONFIRMATION LAMP 0.

This lamp lights up when the fan is rotating in reverse. If the
fan selector switch is operated when the engine is running, this
lamp flashes to warn the operator that the fan operation cannot
be switched.

3-20
OPERATION EXPLANATION OF COMPONENTS

METHOD OF USING DISPLAY PANEL B (Multi-information) 0.

EXPLANATION OF MODES AND CONTROLS 0.
Display panel B (1) has the function of displaying the follow-
ing four types of mode. (The diagram on the right shows
the normal screen before the mode display.)
Maintenance mode
This displays the time for replacing the filters or oil.
PM clinic auxiliary mode
This displays the engine speed and the oil pressure in the
hydraulic circuits.
Fault display mode
This displays the fault code is related to the electronic con-
trol.
Adjustment mode
This adjusts the brightness and contrast of the display.
There are variations (sub-items) in the four types of mode. For an explanation of the variations, see the follow-
ing items.
METHOD OF USING MAINTENANCE MODE ( 3-23 )
METHOD OF USING PM CLINIC AUXILIARY MODE ( 3-24 )
METHOD OF USING FAULT CODE DISPLAY MODE ( 3-24 )
METHOD OF USING USER ADJUST MODE ( 3-25 )
Each mode is operated by using information switch (2) and
buzzer cancel switch (3) on the dashboard in front of the
operator's seat.
After operating the switch, release the switch, and the
switch will return automatically to the center position as
shown in the diagram on the right.
The functions of each position of the switches are as fol-
lows.
<: Moves mode to left
>: Moves mode to right
: Selects mode
…: Cancels mode
The four types of mode can be selected in a cycle by operating information switch (2) to > and < to give the fol-
lowing sequence: Maintenance mode ←→ PM clinic auxiliary mode ←→ Fault code display mode ←→ Adjust-
ment mode ←→ Maintenance mode.
From the normal mode before giving the mode display, if buzzer cancel switch (3) is operated to and held for
2.5 seconds, the maintenance mode is displayed. After that, if information switch (2) is operated to >, the mode
changes to the PM clinic auxiliary mode. If information switch (2) is operated to <, the mode changes to the
user adjust mode.
When any mode is being displayed, if the buzzer cancel switch is operated to …, the screen returns the normal
screen shown before the mode display.

METHOD OF SELECTING MODES 0.

1. When moving from the normal operation display to a user
mode, the maintenance mode is displayed. Use the con-
trols to change the mode as follows.
> position: Go to PM clinic auxiliary mode
< position: Go to user adjust mode
… position: Go to normal operation screen
position: Go to maintenance mode selection screen
20.

3-21
EXPLANATION OF COMPONENTS OPERATION

2. The diagram on the right shows the screen display for the
PM clinic auxiliary mode. Use the controls to change the
mode as follows.
> position: Go to fault code display mode
< position: Go to maintenance mode
… position: Go to normal operation screen
position: Go to PM clinic auxiliary mode selection item
screen

3. The diagram on the right shows the screen display for the
fault code display mode. Use the controls to change the
mode as follows.
> position: Go to adjustment mode
< position: Go to PM clinic auxiliary mode
… position: Go to normal operation screen
position: Go to fault code selection item screen

4. The diagram on the right shows the screen display for the
user adjust mode. Use the controls to change the mode as
follows.
> position: Go to maintenance mode
< position: Go to fault code display mode
… position: Go to normal operation screen
position: Go to user adjust mode selection item screen

3-22
OPERATION EXPLANATION OF COMPONENTS

METHOD OF USING MAINTENANCE MODE 0.

NOTICE
This function is only a guideline. If dirty or oil or filters are found during daily maintenance, replace them
immediately.
If the controllers or monitor panel are replaced, the timer for this function will not work properly. Please
contact your Komatsu distributor for replacement.

The maintenance mode shows the replacement interval for the

oil filters and oil on the monitor.
The content of the display is as follows.
(1) The item is displayed.
(2) The time remaining until replacement is displayed.
(3) The number of times that replacement has been made until
now is displayed.

The display items can be displayed in order by operating the

information switch to the left or right (<, >).

Time to 2nd and

Display Item Time to 1st replacement
following replacements

1. ENG.OIL Engine oil 500h 500h

2. ENG.FLT Engine oil filter 500h 500h

3. FUEL.FLT Fuel filter 500h 500h

4. HYD.FLT Hydraulic oil filter 500h 2000h

5. CORR.FLT Corrosion resistor 1000h 1000h

6. BYPS.FLT Bypass filter (*) 0h 0h

7. DAMP.OIL Damper oil 2000h 2000h

8. OIL Final drive oil 500h 2000h

9. HYD.OIL Hydraulic oil 500h 2000h

10. POWL.OIL Power train oil 500h 1000h

11. POWL.FLT Power train oil filter 500h 500h

12. HSS.FLT HSS charge filter (*) 0h 0h

(*) Although the item of the mark is displayed, it is not used with this machine.
When the oil or filter has been replaced, select the applicable
item, then operate the buzzer cancel switch to .
The screen will ask if you want to display the replacement his-
tory.
Operate the information switch to select YES, then operate the
buzzer cancel switch to . The replacement account will
increase by 1, the replacement interval will be reset, and the
oil, filter change interval lamp will go out.
When this is done, if the maintenance caution lamp does not
go out, there is another item close to the replacement time, so
check the situation.

3-23
EXPLANATION OF COMPONENTS OPERATION

REMARK
To return to the function selection mode, operate the
buzzer cancel switch to ….

METHOD OF USING PM CLINIC AUXILIARY MODE 0.

CAUTION
When moving the work equipment or setting the transmission to the travel position when carrying out
measurements, check carefully that the situation is safe.

The PM clinic auxiliary mode displays the engine speed, hydraulic oil pressure, and other items on display panel
B.
Display panel B displays the item on the top line (1), and the
measured value on the bottom line (2).

The display items consist of the six items in the table below.
The items can be selected by operating the information switch (<, >).

Display Item Measured value

01-ENG.SPEED Engine speed Speed (rpm)

02-BOOST PRESSURE Boost pressure Pressure (kPa)

03-HYD.PUMP PRES Hydraulic oil pressure Pressure (MPa)

04-BATTERY VOLT Battery voltage Voltage (mV)

REMARK
Items such as the engine speed fluctuate and are difficult to see during the measurement. In such
cases, operate the buzzer cancel switch to . This makes it possible to hold the display of the value.
To cancel this mode, operate the buzzer cancel switch again to .
To return to the function selection mode, operate the buzzer cancel switch to ….

METHOD OF USING FAULT CODE DISPLAY MODE 0.

NOTICE
The fault items observed by this function are connected with the electronic control, so even if a fault code
is not displayed, there is probably some problem with the machine. If the operator feels any abnormality
with the machine, the machine should be stopped immediately and checked.

3-24
OPERATION EXPLANATION OF COMPONENTS

When any disconnection or short circuit in any sensor is detected, the location and fault code are displayed by a 6-
digit code on display panel B. When contacting your Komatsu distributor, inform your distributor of the code at the
same time.
If the failure observation function has not grasped the condition
of the machine, the display is as shown in the diagram on the
right.

With this function, existing failures can be displayed up to a

maximum of 20 items.
If multiple failures are occurring, the display automatically
changes every 2 seconds, so check the code.
The display is shown repeatedly.

REMARK
To return to the function selection mode, operate the buzzer cancel switch to ….

METHOD OF USING USER ADJUST MODE 0.

With the user adjust mode, the brightness of the panel screen backlighting and the contrast of the liquid crystal
panel can be changed, or the cooling fan can be set to maximum speed to clean the radiator when it is clogged.
These are displayed on display panel B.

1. Adjusting backlighting of liquid crystal display

The diagram on the right is the mode for adjusting the
brightness of the backlighting of the liquid crystal panel. On
this screen, operate the buzzer cancel switch to to switch
to the screen to adjust the brightness.

The brightness can be adjusted by operating the information

switch.
The higher the number, the brighter the screen becomes; the
lower the number, the darker the screen becomes.
> position: Number increases
< position: Number decreases

3-25
EXPLANATION OF COMPONENTS OPERATION

When the buzzer cancel switch is operated to , the bright-

ness of the liquid crystal display backlighting is set.

2. Adjusting backlighting of message display

The diagram on the right is the mode for adjusting the
brightness of the backlighting of the message display. On
the screen, operate the buzzer cancel switch to to switch
to the screen for adjusting the brightness.

The brightness can be adjusted by operating the information

switch.
The higher the number, the brighter the screen becomes; the
lower the number, the darker the screen becomes.
> position: Number increases
< position: Number decreases

When the buzzer cancel switch is operated to , the bright-

ness of the message display backlighting is set.

3. Adjusting contrast of liquid crystal message display

The diagram on the right is the mode for adjusting the con-
trast of the liquid crystal message display.
On this screen, operate the buzzer cancel switch to to
switch to the screen to adjust the contrast.

3-26
OPERATION EXPLANATION OF COMPONENTS

The contrast can be adjusted by operating the information

switch.
The higher the number, the deeper the screen becomes; the
lower the number, the lighter the screen becomes.
> position: Number increases
< position: Number decreases

When the buzzer cancel switch is operated to , the contrast

of the liquid crystal display is set.

REMARK
To return to the function selection mode, operate the buzzer cancel switch to ….
The brightness of the backlighting of the monitor panel differs according to whether the front lamp is
lighted up or not. Entering this mode when the front lamps are lighted up makes it possible to adjust
the brightness when the front lamps are lighted up. In the same way, entering this mode when the
front lamps are not lighted up makes it possible to adjust the brightness when the front lamps are not
lighted up.

3-27
EXPLANATION OF COMPONENTS OPERATION

SWITCH 0.

(1) Horn switch (4) Cigarette lighter (machines equipped with cab)

(2) Room lamp switch (5) Accessory socket

(3) Wiper switch

HORN SWITCH 0.
The horn sounds when the button (1) at the rear of the blade
control lever at the right side of the operator's seat is pressed.

ROOM LAMP SWITCH 0.

This (2) lights up the room lamp.
ON position: Lamp lights up
OFF position: Lamp is out

ON
OFF

3-28
OPERATION EXPLANATION OF COMPONENTS

WIPER SWITCH 0.
This (3) activates the wipers.
The wiper switches are as follows.
(LH) Left door
(FF) Front window
(RH) Right door
(RR) Rear window
(INT) Wiper intermittent operation switch
This is also used as the window washer switch.
The switch is operated as follows.

Wiper only
If this is switched on, the wiper will start.
ON

OFF

Wiper and window washer

If this is kept pressed to the ON position while the wiper is
working, water will be sprayed out. ON

OFF

REMARK
When installing the cab, check the colors of the washer
tank and window washer hoses, and be sure to connect
correctly.

A Left door (blue) A

B Front window (no color)
B
C Right door (red)

D Rear window (black) Front of

machine C

3-29
EXPLANATION OF COMPONENTS OPERATION

A Red - Right door A

B Blue - Left door
B
C
C Black - Rear window D
D Colorless - Front window E
E Washer tube

F From fuse box red (back up power souce)

Vieuw Y F

CIGARETTE LIGHTER 0.
This (4) is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its origi-
nal position after a few seconds, so take it out to light your cig-
arette.
Cigarette lighter capacity: 120W

NOTICE
This cigarette lighter is 24V. Do not use it as the power
source for 12V equipment.

ACCESSORY SOCKET 0.
This (5) is used as the power source for a wireless or other 12V
equipment.

Accessory socket capacity: 60W (12V x 5A)

3-30
OPERATION EXPLANATION OF COMPONENTS

CONTROL LEVERS, PEDALS 0.

(1) Fuel control dial (5) Parking lever

(2) Joystick (steering, directional and gear shift lever) (6) Safety lever

(3) Brake pedal (7) Blade control lever

(4) Deceleration pedal (8) Ripper control lever

FUEL CONTROL DIAL 0.

This dial (1) is used to control the engine speed and output.
(a) Low idling position: Turn fully to the left
(b) High idling position: Turn fully to the right MAX

REMARK
When stopping the engine, set the starting switch to the
OFF position.

MIN

3-31
EXPLANATION OF COMPONENTS OPERATION

JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) 0.

(PCCS lever)
This lever (2) is used to switch between forward and reverse to
steer and gear shift the machine or carry out counter rotation
turns.

REMARK
PCCS: Palm command control system

Forward-reverse shifting
Position (a): FORWARD
Position (b): REVERSE
Position N: Neutral
Operate to the front to drive forward; operate to the rear to
drive in reverse.
Steering
(L) Left turn
(R) Right turn
With the lever operated to the front or rear, operate the lever partially to the left or right to turn the machine. The
machine will turn gradually in the same direction as the lever is operated.
If the lever is operated fully to the left or right, the machine will turn in a small radius.

REMARK
If the lever is released when steering the machine, the lever will return to the (a) position or the (b) posi-
tion and the machine will be returned to straight movement.

Gear shifting
When the steering, directional, and gearshift lever is at the
FORWARD or REVERSE position and switch (c) or switch (d)
is pushed, the transmission speed will change.
UP switch (c): Each time the switch is pressed, the transmis-
sion will shift up one speed.
DOWN switch (d): Each time the switch is pressed, the trans-
mission will shift down one speed.
For details of the maximum speed in each speed range, see
“SPECIFICATIONS ( 5-2 )“.

REMARK
The speed range being used is displayed on the monitor panel according to the gearshift operation.
<Example>
Neutral: N is displayed on the display panel.
FORWARD 2nd: F2 is displayed on the display panel.
REVERSE 3rd: R3 is displayed on the display panel.
When the parking lever is locked, P is displayed.
For details of the method of shifting gear according to the shift mode, see the “SHIFTING GEAR ( 3-82
)“. Shift mode selection means that the selected speed range is displayed at the N position before
starting.

3-32
OPERATION EXPLANATION OF COMPONENTS

Operating counterrotation turn

WARNING
When operating the counterrotation turn, if the load on the
left and right is not balanced, the machine may make a
pivot turn, so check the ground conditions and be careful
not to hit any obstacles when carrying out the operation.

With the lever at the N position, operate the lever partially in

the direction of turn. The left and right tracks will rotate in
opposite directions, and the machine will make a slow counter-
rotation turn. If the lever is operated further, the speed of the
counterrotation turn will increase.
(R): Right counterrotation turn
(L): Left counterrotation turn

BRAKE PEDAL 0.

WARNING
Do not place your foot on this pedal unnecessarily.

Depress the pedal (3) to apply the right and left brakes.

DECELERATION PEDAL 0.

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 (4) is used when reducing the engine speed or stop-
ping the machine.
When switching between forward and reverse, or when stop-
ping the machine, use this pedal to reduce speed.

3-33
EXPLANATION OF COMPONENTS OPERATION

PARKING LEVER 0.

WARNING
When the machine is parked, always set the parking lever
to the LOCK position.

This lever (5) is used to apply the parking brake.

Free
REMARK Lock
When operating the parking lever to the LOCK position,
return the steering, directional, and gearshift lever to
the N position first.
When starting the engine, if the parking lever is not at
the LOCK position, the limit switch is actuated and it is
impossible to start the engine.

SAFETY LOCK LEVER 0.

WARNING
When standing up from the operator's seat, always set
the safety lever securely to the LOCK position. Free
If the blade control and ripper control levers are not
locked and are touched by accident, it may lead to
serious injury or damage.
Lock
If the safety lever is not set securely to the LOCK posi-
tion, 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 main-
tenance, always lower the blade and ripper to the
ground, then set the safety lever to the LOCK position.

This safety lever (6) 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.

REMARK
When starting the engine, to ensure safety, always set the safety lever to the LOCK position.

BLADE CONTROL LEVER 0.

This lever (7) is used to raise the blade.
Single tiltdozer

3-34
OPERATION EXPLANATION OF COMPONENTS

This lever is used to raise or tilt the blade.

Lifting control
(a) RAISE:
(b) HOLD:
Blade is stopped and held in this position. Raise
(c) LOWER:
(d) FLOAT:
Blade will move freely according to external force.

REMARK Lower
When released form FLOAT position, this lever will not
return to HOLD position, so it must be moved back by
hand.
TILT OPERATION
(A) RIGHT TILT
(B) LEFT TILT

Right tilt

Left tilt

RIPPER CONTROL LEVER 0.

This lever (8) is used to operate the ripper.
(a) RAISE
(b) HOLD: Ripper is stopped and held in the same position.
(c) LOWER

Raise

Lower

3-35
EXPLANATION OF COMPONENTS OPERATION

DUST INDICATOR 0.
This is on the air cleaner bracket inside the engine room.
This device indicates that the air cleaner element is clogged.
For details on how to clean the element, see “CHECK, CLEAN
AND REPLACE AIR CLEANER ELEMENT ( 4-21 )“.

3-36
OPERATION EXPLANATION OF COMPONENTS

FUSE BOX 0.
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.

The fuses protect the electrical equipment and wiring from burning out.
If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the
fuse.
Replace a fuse with another of the same capacity.
Fuse boxes is installed under the battery cover.
Circuit breaker is installed the recirculated air filter cover.
(1) Fuse box FS1
(2) Fuse box FS2

(3) Circuit breaker

Cab (machines equipped with cab)

Fuse box is installed at the bottom of the overhead panel.

3-37
EXPLANATION OF COMPONENTS OPERATION

CIRCUIT BREAKER 0.
If the starting switch does not work even when the starting
switch is turned to the ON position, open the recirculated air
filter cover.
If excessive current flows through the circuit breaker, it cuts
off the electric circuit to prevent damage to the electrical
components and wiring.
To restore the electric circuit after it has been cut off, push in
reset button (3). (This springs out when the circuit is cut
off.)
If the electric circuit is normal, reset button (3) will stay
pushed in. If it comes out immediately when it is pushed in,
the electric circuit must be checked.

Fuse
No Circuit
capacity

(1) 20A Starting switch

(2) 20A Air conditioner

REMARK
The circuit breaker is a device installed in electric circuits where a large current flows. It is installed to
protect the electric circuit. It protects the electric components and wiring from damage caused by an
abnormal current in the same way as a normal fuse. After repairing and restoring the location of the
abnormality, there is no need to replace the breaker. It can be used again.

FUSE CAPACITY AND NAME OF CIRCUIT 0.

FUSE BOX I 0.
(1) Fuse box fs1

Fuse
No. Circuit
capacity

1 30A Additional heater, Spere power source

2 20A Horn, Intake air heater

3 20A Head lamp

4 20A Rear lamp

5 20A Transmission Steering controller

(2) Fuse box fs2

Fuse
No. Circuit
capacity

(1) 15A Monitor panel

(2) 20A Fuel pump

(3) 30A Air conditioner

(4) 20A Backup alarm

(5) 30A Battery power source (direct from battery)

3-38
OPERATION EXPLANATION OF COMPONENTS

FUSE BOX II 0.

Fuse
No. Circuit
capacity

(1) 10A Radio memory

(2) 20A Radio, lamp, cigarette lighter

(3) 20A Rear heating wire glass (If equipped)

(4) 10A Rear wiper

(5) 10A Front wiper

(6) 10A Left and right door wiper

FUSIBLE LINK 0.
If the starting motor does not work even when the starting
switch is turned to the ON position, there may be a disconnec-
tion in fusible links (2) and (3) on top of the wiring, so remove
the cover (1) at the side of the battery box cover on the left
side of the machine and check or replace.

Capacity of (2): 32 A
Capacity of (3): 96 A

REMARK
A fusible link refers to the large-sized fuse wiring installed in the high current flow portion of the circuit to
protect electrical components and wiring from burning, similarly to an ordinary fuse.

3-39
EXPLANATION OF COMPONENTS OPERATION

DOOR OPEN LOCK 0.

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

2. To release the door, move lever (2) inside the cab to the
front of the cab. This will release the catch.

NOTICE
When keeping the door open, fix it securely to the
catch.
Always close the door when traveling or carrying out
operations. Leaving the door open will cause the door
to break.
Keep the door locked open securely. The door may
swing closed because of the vibration.

SASH GLASS INTERMEDIATE LOCK 0.

When working with the cab sash glass open, use this lock to
prevent the glass from chattering.
When the lever is at the FREE position, the glass can be
opened or closed.
When the lever is moved to the LOCK (up or down) position,
the glass is fixed in position.

NOTICE
Always close the window when traveling or carrying out
operations. Leaving the window open will cause the win-
dow to break.

Free

Lock

3-40
OPERATION EXPLANATION OF COMPONENTS

DOOR POCKET 0.
This is inside the left and right doors. Use it for keeping things.
Do not put the heavy tools or other heavy objects in it.
If the pocket is dirty, loosen three bolts (1), then remove the
pocket and rinse it.

ASHTRAY 0.
This is on the left side of the operator's seat.
Always make sure that you extinguish the cigarette before clos-
ing the lid.

3-41
EXPLANATION OF COMPONENTS OPERATION

CAR STEREO, HANDLING 0.

EXPLANATION OF COMPONENTS 0.

(1) Power switch/volume (8) Cassette door

(2) Auto-store/preset scan button (9) Fast forward, rewind buttons
(3) Bass control knob (10) Preset buttons
(4) Treble control knob (11) Metal tape button
(5) Loudness button (12) Manual tuning buttons
(6) Time/radio display selector button (13) Seek tuning buttons
(7) Tape eject button (14) Band selector button

(A) Band display (E) Tape direction display

(B) Metal tape display (F) Preset channel display
(C) FM stereo reception display (G) Time/frequency display
(D) Loudness display

3-42
OPERATION EXPLANATION OF COMPONENTS

POWER SWITCH/VOLUME 0.
Turn this knob (1) to the right until it clicks to turn the power on.
Turn it further to increase the volume.

AUTO-STORE/PRESET SCAN BUTTON 0.

Use this button (2) to actuate the preset scan and auto-store
functions.
Auto-store
Each time this button is pressed for more than 2 seconds
while in radio reception, this auto-store function automati-
cally starts to search for the desired station within a receiv-
able band, and memorize the frequency in the preset
memory. During this scanning process, the frequency
shown in the right side of display continues to change. This
indicates that each frequency is memorized in the auto-
store.

REMARK
The auto-store function cannot be used when the channel
display is flashing.
When the display is flashing, the preset scan function is
being used.

BASS CONTROL KNOB 0.

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

TREBLE CONTROL KNOB 0.

Turn this button (4) to the left to reduce the low tones; turn it to
the right to emphasize the high tones.
Direction (a): High tone reduced
Direction (b): High tone emphasized

3-43
EXPLANATION OF COMPONENTS OPERATION

LOUDNESS BUTTON 0.
This button (5) is used when playing at low volume. It makes it
possible to hear more easily by emphasizing the low tone when
the low tones are weak.
Push button : Actuated (ON)
Push button again : Canceled (OFF)

TIME/RADIO DISPLAY SELECTOR BUTTON 0.

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

Correcting time
Press the button to set to the time display.
(A) Correcting hour :
Keep the DISP button pressed and press the bottom tuning
button (H) to correct the hour.
(B) Correcting minute :
Keep the DISP button pressed and press the top tuning but-
ton (M) to correct the minute.

TAPE EJECT BUTTON 0.

This button (7) is used to stop the tape and to eject the cas-
sette.
When this button is pressed, the tape is ejected and the radio
plays.

3-44
OPERATION EXPLANATION OF COMPONENTS

CASSETTE DOOR 0.
Set the cassette with the exposed portion of the tape on the
right side and insert it in cassette door (8).

FAST FORWARD, REWIND BUTTONS 0.

These buttons (9) are used to fast forward or rewind the tape.
Fast forward/rewind
If you press the button pointing in the same direction as the
arrow indicating the direction of play, the tape will be fast
forwarded; if you press the button pointing in the opposite
direction, the tape will be rewound.
To stop the tape, lightly press the button that is not locked.
The fast forward or rewind operation will be canceled.

PRESET BUTTONS 0.
These buttons (10) are used to call up the broadcast station
frequencies preset in memory for each of buttons No.1 to No.6.
It is possible to preset 18 stations (FM:12; AM:6) with these
buttons.

METAL TAPE BUTTON 0.

(used also for preset button No.5)
This button (11) is used when playing a metal or chrome tape.
This button is used also for preset button No.5. When it is
pressed, “MTL“ appears on the display.

3-45
EXPLANATION OF COMPONENTS OPERATION

MANUAL TUNING BUTTONS 0.

These buttons (12) are used for manual tuning.
When “TUN /\“ button is pressed, the frequency goes up 9 kHz
for AM or 0.1 MHz for FM; when “TUN \/“ button is pressed, the
frequency goes down 9 kHz for AM or 0.1 MHz for FM.
If the button is pressed down and held, the frequency will
change continuously.

SEEK TUNING BUTTONS 0.

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

BAND SELECTOR BUTTON 0.

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

3-46
OPERATION EXPLANATION OF COMPONENTS

METHOD OF OPERATION 0.
METHOD OF SETTING PRESET BUTTONS 0.
To listen to a preset station, use band selector button (1) to
select AM, FM1, or FM2, then press the preset switch number
to listen to the desired station.
It is possible to preset six AM stations and 12 FM stations
(FM1: 6, FM2: 6).
1. If you are playing a cassette, press the tape eject button to
stop the tape.
2. Select the station to be preset.
Use band selector button (1) to select MW (AM), FM1, or
FM2, then use the manual tuning button to select the fre-
quency of the broadcasting station.
3. Press manual memory button (2) or seek tuning button (3).
4. Press preset button (4) of the number to be preset for 2 sec-
onds while the frequency display is being shown on the dis-
play. (The preset channel and frequency are displayed and
the presetting is completed).
5. Repeat Steps 2 to 4 to preset other stations.

REMARK
Use Steps 2 to 4 also when changing the setting of a
preset switch to another station.
When the power is disconnected, such as when the bat-
tery is replaced, all the settings are deleted, so preset
the stations again.

MANUAL MEMORY BUTTON 0.

Select the station to be preset with manual tuning button (1) or
seek tuning button (2), then keep button No.1 to button No.6 of
button (3) pressed for 2 seconds while the frequency is being
displayed to preset the station.

3-47
EXPLANATION OF COMPONENTS OPERATION

LISTENING TO RADIO 0.
1. Turn the starting switch ON, then turn power switch (1) ON.
2. Set band selector button (2) to AM or FM.
3. Select the station with the preset buttons or manual tuning
button (3).
4. Adjust the volume, balance, and tone as desired.
5. When turning the radio OFF, turn power switch (1) to the left
until there is a click.

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

LISTENING TO CASSETE TAPE 0.

1. Turn the starting switch ON, then turn power switch (1) ON.
2. Set the cassette with the exposed portion of the tape on the
right side and push it into the cassette door. The tape will
automatically start playing.
If the arrow indicating the direction of play is pointing to the
right, the top side is being played; if the arrow is pointing to
the left, the bottom side is being played.
When the tape reaches the end, it is automatically reversed
and the other side starts to play.
3. When finishing with the tape, press the cassette eject button
to eject the tape and automatically switch to the radio.

3-48
OPERATION EXPLANATION OF COMPONENTS

REVERSING TAPE 0.
When listening to the tape, press both FAST FORWARD,
REWIND buttons (A) and (B) at the same time lightly.
When this is done, the tape direction display will be reversed.

PRECAUTION WHEN USING 0.

WARNING
If a voltage greater than the specified voltage is input, it may cause fire, electrocution, or other failure.
Never input any voltage other than the specified voltage.
Places inside the radio are under high voltage. Do not remove the cover.
Do not carry out any modification. This may cause fire, electrocution, or other failure.
If the sound cannot be heard, no display is given, or any other abnormality occurs, turn off the power
switch and ask your Komatsu distributor as soon as possible to carry repairs.

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

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

3-49
EXPLANATION OF COMPONENTS OPERATION

AIR CONDITIONER 0.
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL 0.

DEF

DEF DEF

DEF DEF

Temperature level FOOT

indicator lamp

(1) Fan switch (3) Fresh/recirc selector switch

(2) Air conditioner switch (4) Temperature control switch

FAN SWITCH 0.
This switch (1) can be used to adjust the air flow to four stages.
It also acts as the main switch for the air conditioner. When the
OFF switch is pressed, the fan stops.
When the switch is pressed, the indicator lamp above the
switch lights up to display the air flow.

3-50
OPERATION EXPLANATION OF COMPONENTS

AIR CONDITIONER SWITCH 0.

This switch (2) is used to start or stop the cooling or dehumidi-
fying function.
When the fan switch is turned ON and the air conditioner
switch is pressed, the indicator lamp above the switch lights up.
When the switch is pressed again, the switch is turned OFF
and the indicator lamp goes out.
REMARK
When fresh air is taken into the cab, air pressure in the cab
increases, which prevents the dust from entering. When
neither heating nor cooling is needed, bring in clean fresh
air to prevent the dust from coming in with your preferred
air flow.

FRESH/RECIRC SELECTOR SWITCH 0.

This switch (4) changes between internal air circulation and external air intake.
When pressing the switch, the indicator lamp on the top of switch lights up.

Internal air circulation

This switch (4) is used when wishing to quickly cool or warm
the cab or when the air inside the cab is stale.

External air intake

This switch (4) is used to cool or warm the cab with the external
air intake. Also, it is used for fresh air intake or to remove con-
densation on windows.

TEMPERATURE CONTROL SWITCH 0.

The temperature can be adjusted with this switch (5) by press-
ing and holding the up or down button.
The temperature level indicator lamps light up to display the
temperature of the air coming from the vents.
The more the blue lamps light up, the lower the temperature is.

The color of the indicator lamp changes while the switch is

being pressed.
When the temperature reaches the desired level, release the
switch to set the temperature.

The settings for each mode are retained in memory even when the starting switch is turned OFF.
However, in the following cases, the settings must be made again.
When the machine has been out of use for more than 7 days
When the battery voltage is extremely low
When there has been abnormal interference from outside

3-51
EXPLANATION OF COMPONENTS OPERATION

When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch)

If the air conditioner is used at the FRESH position, the inside of the cab will be pressurized and this will prevent
the entry of dust.
The higher the position of the fan switch, the more effective the pressurizing becomes.

METHOD OF OPERATION 0.

Switch
Air conditioner Temperature FRESH/RECIRC
Fan switch
switch control switch selector switch
Condition of use

Rapid HI ON All blue RECIRC

Cooling More than half
Normal HI - LO ON FRESH
are blue

Dehumidifying, More than half

HI - LO ON FRESH
heating are red

Rapid HI OFF All red RECIRC

Heating More than half
Normal HI - LO OFF FRESH
are red

More than half

Defroster HI ON FRESH
are red

Vetilation or pres-
HI - LO OFF All blue FRESH
surizing

When carrying out the defrosting, if the temperature control

switch is set so that all lamps are red, this will improve the per-
formance for defrosting and demisting.

WHEN NOT USING THE AIR CONDITIONER REGULARLY 0.

Run the air conditioner at cooling or dehumidification + heating for several minutes from time to time to prevent the
loss of the oil film at various parts of the compressor.

REMARK
If the temperature inside the cab is low, the air conditioner may not work. In such cases, use the recircu-
lated air to heat up the inside of the cab, then turn the air conditioner switch on to run the air conditioner.

3-52
OPERATION EXPLANATION OF COMPONENTS

COOL BOX 0.
When the cooling is being used, this can be used for keeping
drinks and other things cool.
When the heating is being used, it can be used to keep things
warm.
When not using the box, close the grill.
Do not use the cool box for things which smell or leak water or
break easily.
Do not use it as a holder for tools or other small objects.

PRECAUTIONS WHEN USING 0.

PRECAUTIONS WHEN USING THE COOLING 0.
If you smoke when using the air conditioner, your eyes may start to itch or burn, therefore ventilate the cab
every so often to remove the smoke.
When using the air conditioner for a long period of time, carry out ventilation process at least once every hour.
When using the air conditioner, it is recommended for health reasons, that it should only feel slightly cooler
(5 or 6°C lower than the outside temperature) when you enter the cab.
Therefore, to adjust the temperature to a suitable level.

SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SUR-
FACE 0.
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, close the louvers of the vent and change the direction to prevent the cold air from playing
directly on the surface of the glas.

CHECKS DURING OFF-SEASON 0.

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 con-
trol lever at the central position.)

REMARK
When the ambient temperature is low, if the compressor is suddenly run at high speed, it may cause fail-
ure 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 to 6.5°C.

PROCEDURE FOR REPLACING RECEIVER 0.

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
The replacement interval may become shorter depending on the condition of use.
If the receiver is used when the moisture absorption limit of the desiccant has been exceeded, the
refrigerant circuit may become blocked and cause the compressor to break down.

PRECAUTIONS WHEN REPLACING RECEIVER 0.

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.
When removing the refrigerant from the refrigerant circuit, release it gradually from the low pressure side to
prevent oil from flowing out.

3-53
EXPLANATION OF COMPONENTS OPERATION

CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL 0.

If the compressor belt is loose, or the refrigerant level is low, cooling is not carried out efficiently.
For details, see “WHEN REQUIRED ( 4-19 )“.

CLEANING AIR FILTER 0.

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 “WHEN REQUIRED ( 4-19 )“.

ACCUMULATOR, HANDLING 0.
WARNING
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 lever and parking lever in the LOCK position.
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explo-
sion, which will lead to serious injury or damage. When handling the accumulator, always do as follows.
The pressure in the control circuit cannot be completely removed. When removing the hydraulic
equipment, do not stand in the direction that the oil spurts out when carrying out the operation.
Loosen the bolts slowly.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it or weld it.
Do not hit it, roll it, or subject it to any impact.
When disposing of the accumulator, the gas must be released. Please contact your Komatsu distribu-
tor to have this work carried out.

The accumulator is a device to store the pressure in the control

circuit, and when it is installed, the control circuit can be oper-
ated 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 dia-
gram on the right.

METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE

EQUIPPED WITH ACCUMULATOR 0.
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 where the oil may spray out.

3-54
OPERATION OPERATION

OPERATION 0.
CHECK BEFORE STARTING ENGINE, ADJUST 0.
WALK-AROUND CHECK 0.
Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leak-
age 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.

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 operator's compartment. Always use the handrail and step at
the side when getting on or off the machine.

If the machine is at an angle, make it horizontal before checking.

Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leak-
age 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 in this section before starting the engine each day.

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 flamma-
ble 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 abnor-
mality is found, repair it.
4. Check for 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 roll-
ers
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.

3-55
OPERATION OPERATION

CHECK BEFORE STARTING 0.

Always carry out the items of the checks in this section before starting the engine each day.

CHECK MONITOR PANEL 0.

1. Turn starting switch (1) to the ON position.
2. Check that all monitor and gauge light up for 2 seconds, the
warning lamp lights up for 1 seconds, and the alarm buzzer
sounds for 2 second.

REMARK
If the lamps do not light up, there may be a failure or dis-
connection in the monitor, so please contact your
Komatsu distributor.

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.

3-56
OPERATION OPERATION

CHECK COOLANT LEVEL, ADD WATER 0.

WARNING
Normally, do not open the radiator cap. When checking the cooling water level, check the sub-tank
when the engine is cold.
Do not remove the cap when the radiator water is hot. Boiling water may spurt out. After the water
temperature goes down, turn the cap slowly to release the pressure, then remove it.

1. Open the engine side cover on the left side of the chassis,
and check that the coolant is between the FULL and LOW
marks on sub-tank (1). If the water level is low, add water to
the FULL level through the water filler port in sub-tank (1).

REMARK
The coolant may overflow from the sub-tank drain hose.
This is no problem. It occurs because too much coolant
has been added.

2. After adding coolant, tighten the cap securely.

FULL

LOW

3. If the sub tank is empty, first check for leakage of water,

then remove radiator cap (2) and check that the coolant
water is above the bottom surface of the strainer as shown
in the diagram on the right. Add water if the level is low.
4. After adding water, close the engine side cover.

Radiator
Strainer

3-57
OPERATION OPERATION

CHECK FUEL LEVEL, ADD FUEL 0.

WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If the fuel is spilt, wipe it off com-
pletely.

1. Turn the engine starting switch to the ON position and

check the fuel level with fuel level gauge (G) on the monitor
panel.
After checking, turn the switch back to the OFF position.

2. After completing work, fill the fuel tank through fuel filler port
(F).
3. After adding fuel, tighten the cap securely.
Fuel capacity: 490 liters

REMARK
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.
If breather hole (1) on the cap is clogged, the pressure
in the tank will drop and fuel will not flow.
Clean the hole from time to time.

3-58
OPERATION OPERATION

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 0.

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious
burns. Wait for the temperature to go down before starting the operation.

1. Open the engine side cover on the left side of the chassis.
2. Remove dipstick (G), and wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.

4. The oil level should be between the H and L marks on dip-

stick (G).
If the oil level is below the L mark, add engine oil through oil
filler (F).

5. If the oil is adove the H mark, drain the excess engine oil
from drain plug (1), and check the oil level again.
6. If the oil level is correct, tighten the oil filler cap securely and
close the engine side cover.

REMARK
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stop-
ping the engine before checking.
If the machine is at an angle make it horizontal before checking.
When adding oil, remove the dipstick form the holder to release the air inside the crankcase.

3-59
OPERATION OPERATION

CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL 0.

1. Remove dipstick (G), and wipe the oil off with a cloth.
2. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.
3. Check that the oil level is between the top and bottom
marks on dipstick (G).
If the oil level is below the bottom mark, add engine oil
through the dipstick holder.

4. If the oil is above the H line, remove drain cover (1) at the
left side at the bottom surface of the power train case,
loosen drain plug (2), drain the excess oil, then check the oil
level again.
5. If the oil level is correct, tighten the oil filter cap securely.

REMARK
When inspecting, if the machine is at an angle, move it to a
horizontal place to carry out the check.

CHECK BRAKE PEDAL TRAVEL 0.

Drive the machine, depress the brake pedal, and check that the machine stops.

3-60
OPERATION OPERATION

CHECK DUST INDICATOR 0.

1. Check that the yellow piston inside the red zone on the out-
side diameter of dust indicator (1) is not overlapping.
2. If the yellow piston is overlapping the red zone, clean or
replace the element immediately.
For details of the method of cleaning the element, see
“CHECK, CLEAN AND REPLACE AIR CLEANER ELE-
MENT ( 4-21 )“.

3. After checking, cleaning, and replacing, press the knob of

dust indicator (1) to return the yellow piston to its original
position.
In environments where the rubber deteriorates quickly or
the surface becomes damaged (in direct sunlight, dusty
areas, etc.), replace before it becomes dirty and it
becomes difficult to judge the condition.

3-61
OPERATION OPERATION

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL 0.

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.
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 (P), loosen drain valve (1),
and drain the excess oil.

1. Lower the blade to the ground and stop the engine. Wait for
about 5 minutes before checking oil level. If the oil level
should be between H and L in sight gauge (G).

NOTICE
If the oil level is above the H line, do not add oil. Doing so
may lead to damage to the oil pressure circuit and spout-
ing out of oil.

2. If the level is below the L mark, add engine oil through oil
filler (F).

REMARK
When inspecting, if the machine is at an angle, move it to a
horizontal place to carry out the check.

Proper range

3-62
OPERATION OPERATION

CHECK ELECTRIC WIRINGS 0.

WARNING
If fuses are frequently blown or if there are traces of short circuit on the electrical wiring, locate the
cause and carry out repair, or please contact your Komatsu distributor.
Accumulation of flammable material (dead leaves, twigs, grass, etc.) around the battery may cause
fire, so always check and remove such material.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is
clogged with dirt or dust, wash the battery cap to clear the breather hole.

Check that there is no damage to the fuse, that a fuse of the specified capacity is being used, that there are no
signs of any disconnection, breakage, or short circuit in the electric wiring, check for any loose terminals, and
tighten any loose terminals that are found.
Be particularly careful to check the wiring for the battery, starting motor, and alternator.
In addition, if any flammable material is accumulated around the battery, remove it.
For repairs or investigation of the cause, please contact your Komatsu distributor.

CHECK THAT LAMPS LIGHT UP 0.

1. Turn the starting switch key to the ON position.

2. Turn the front lamp and working lamp switch to the ON (b)
position and check that the front lamps and working lamp
light up.

3. Turn the rear lamp switch to the ON (b) 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 dis-
tributor for repairs.

3-63
OPERATION OPERATION

CHECK HORN SOUND 0.

1. Turn the starting switch key to the ON position.

2. Push the horn switch and check that the horn sounds.

CHECK BACKUP ALARM SOUND 0.

1. After starting the engine, run it at idling, depress the brake
to the fullest extent, and set the parking lever free.

2. While depressing the brake pedal to the fullest extent, 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 posi- Reverse
tion.
3. As soon as it is confirmed that the buzzer is working prop-
erly, set the joystick to the NEUTRAL position, put the park-
ing lever to the LOCK position, and then release the brake
pedal.

3-64
OPERATION OPERATION

ADJUSTMENT 0.
ADJUSTING OPERATOR'S SEAT 0.

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 operator's back against
the backrest.

(A) Fore-and-aft adjustment

Pull lever (1), set the seat to a position where it is easy to oper-
ate, then release the lever.
Fore-aft adjustment: 200 mm (10 stages)

(B) Weight and height adjustment of seat

Turn knob (2) under the seat so that weight adjustment indi-
cator (3) displays the green range. The height can be
adjusted by turning the knob (2) while the green range is
displayed.
Turn the knob clockwise to raise the seat and turn the knob
counterclockwise to lower the seat.
Height adjustment range: stepless, 75 mm
Weight adjustment range: 50 to 130kg

(C) Adjust reclining angle

REMARK
When the seat is pushed forward, the available reclining angle becomes greater; when the seat is pushed
back, the available reclining angle becomes smaller. When moving the seat back, return the seat back to
its original position before moving the seat.

Pull up lever (4), set the seatback to a position where it is easy to operate, then release the lever.

(D) Adjusting direction of seat

Pull up lever (5) to unlock the seat, and the seat can be turned
by hand to the position of 15° on the right.
After changing the direction of the seat, return the lever
securely to lock the seat.
Change the direction of the seat to the right for the ease of
operation of the ripper.

3-65
OPERATION OPERATION

USING SEAT BELT 0.

WARNING
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.
Even if no abnormality can be seen in the belt, replace the seat belt every 3 years. The date of manu-
facture of the belt is shown on the back of the belt.
Adjust and fasten the seat belt before operating the machine.
Always sure seat belt when operating the machine.
Fit the seat belt across your lap without twisting.

FASTEN THE BELT AND REMOVE IT 0.

1. Sit on the seat, depress the brake pedal fully, and adjust the
seat so that your back is pressed against the backrest.
2. After adjusting the seat position, adjust tether belt (1). Tense
the tether belt and install it when there is no one sitting on
the seat.
3. Sit on the seat and hold tongue (4) connected to wind-in
mechanism (2) and pull out the belt slowly so that the belt
will cover your abdomen sufficiently.
4. Insert tongue (4) in buckle (3) until it clicks. The belt is
pulled back into wind-in mechanism (2) until it is fitted to
your abdomen. The belt is locked under this condition and
cannot be extended anymore. Fit the belt to your abdomen
without twisting it.

REMARK
If the belt is locked before the tongue is inserted in the
buckle, let it return to the wind-in mechanism, then repeat
the above procedure from the first.

5. Pull the belt to check that it is securely locked in position.

6. When removing the belt, press the red button on buckle (3).
The belt will automatically be wound in.
Check the mounting bolts of the belt fitting on the machine body for looseness, and re-tighten them if necessary.
Tightening torque: 24.5 ± 4.9 N·m (2.5 ± 0.5 kgf·m)
If the seat is scratched or frayed or if any of the fittings is broken or deformed from long service, replace the seat
belt immediately.

ADJUST MIRROR 0.
Loosen nut (1) of the mirror and adjust the mirror to a position
where it gives the best view from the operator's seat.
In particular, be sure to adjust the mirror so that people at the
rear left or right of the machine can be seen clearly.

3-66
OPERATION OPERATION

ADJUST JOYSTICK (PCCS LEVER) 0.

WARNING
After moving case (2) in order to adjust the position of the steering, directional, and gearshift lever, check
that lock lever (1) is fitted securely in the notch hole when securing it. Check that it is in the LOCK posi-
tion. If the lock condition is not complete, the steering, directional, and gearshift lever may move at an
unexpected time and cause serious injury or damage.

The steering, directional, and speed lever (wrist control type single lever: joystick) can be adjusted by 90 mm in 9
stages to the front or rear. Adjust to the most suitable position to match the adjustment of the operator's seat.
1. Pull up lock lever (1) at the rear of case (2) on the left side of
the operator's compartment and make it free.
Free

Lock

2. Keep lock lever (1) pulled up and use your other hand to
grip the front of case (2), then move it to the front with your
left and right hands. The joystick moves together with the
case.
3. When moving, set to the desired position of the positions
where a click can be heard. Then pull up lock lever (1) and
Front
release it. Lock lever (1) returns automatically to the LOCK
position.
Rear

REMARK
PCCS: Palm command control system

ADJUST ARMREST 0.
The height of the armrest on the left and right sides of the operator's seat can be adjusted to 3 positions. After
adjusting the operator's seat, adjust the armrest to a suitable height.

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OPERATION OPERATION

ADJUST ARMREST (RIGHT) 0.

Armrest (1) on the right side of the operator's cab part can be adjusted up 30 mm or down 30 mm based on the
standard height (center) in three stages.
1. Loosen knob (2) (two places).

2. Move the armrest on the operator's seat to the front, then

align the position of the 3 holes (high, middle, low).
3. Tighten knob (2) securely.

Low

Middle

High

ADJUST ARMREST (LEFT) 0.

The armrest on the left side of the operator's compartment can be adjusted to 2 heights.
It is possible to adjust the standard height up 30 mm or down 30 mm steplessly.
The joystick moves as a unit.

Turn up/down left adjustment knob (1) to adjust the height.

Turn the knob to adjust as follows.
Turn CLOCKWISE to move DOWN
Turn COUNTERCLOCKWISE to move UP

3-68
OPERATION OPERATION

OPERATIONS AND CHECKS BEFORE STARTING ENGINE 0.

WARNING
When starting the engine, check that the safety lock
lever and parking lever is securely at the LOCK posi-
tion.
If the control levers are not locked and they are
touched by accident when starting the engine, the
work equipment may move unexpectedly, and this
may lead to a serious injury or death.
When standing up from the operator's seat, always set
the safety lock lever to the LOCK position, regardless
of whether the engine is running or stopped.

1. Check that parking lever (1) is locked. If this lever is not at

the LOCK position, the engine will not start.

Free
Lock
2. Check that joystick (2) is at the 1st position.

REMARK
The engine cannot be started if joystick (steering, directional, and gearshift lever) (2) is not at the N posi-
tion.
If joystick (steering, directional, and gearshift lever) (2) is at F or R, the letter P on display panel A will
flash.

3-69
OPERATION OPERATION

3. Check that the blade is lowered to the ground and that

blade control lever (3) is at the HOLD position. If it is at the Float Lower
FLOAT position, the engine will not start. Hold

Raise

Raise

Lower

4. Check that the ripper is lowered to the ground.

5. Check that safety lever (4) is locked.
If safety lever (4) is locked, the blade control lever is
returned to the HOLD position even if it is at the FLOAT
position.

Free

Lock

3-70
OPERATION OPERATION

STARTING ENGINE 0.
NORMAL STARTING 0.

WARNING
Start the engine only after sitting down in the opera-
tor's seat.
Do not attempt to start the engine by short-circuiting
the engine starting circuit. Such an act may cause
serious bodily injury or fire.
Check that there are no persons or obstacles in the
surrounding area, then sound the horn and start the
engine.
Exhaust gas is toxic. When starting the engine in con-
fined spaces, be particularly careful to ensure good
ventilation.

NOTICE
Do not crank the starting motor continuously for more
than 20 seconds. If the engine does not start, wait for at
least 2 minutes, then repeat the procedure from Step 2.
Before starting the engine, check that the fuel control
dial is at the low idling (MIN) position.
On this machine, to protect the turbocharger, a turbo
protect function is provided. In cold weather, even if
fuel control dial (1) is operated immediately after start-
ing the engine, the engine speed may not change for
several seconds.
If the fuel control dial is at the FULL position, the
engine will accelerate suddenly and cause damage to
the engine parts, so set it to an intermediate or low
speed position.

1. Turn fuel control dial (1) to the center position between MIN
and MAX position.

Mid-
range
speed

MIN
Low idling

2. Turn the key of starting switch (2) to the START position.

3-71
OPERATION OPERATION

3. When engine is started, release the key of starting switch

(2) and the key will return automatically to ON.

STARTING IN COLD WEATHER 0.

WARNING
Start the engine only after sitting down in the opera-
tor's seat.
Do not attempt to start the engine by short-circuiting
the engine starting circuit. Such an act may cause a
serious bodily injury or fire.
Check that there are no persons or obstacles in the
surrounding area, then sound the horn and start the
engine.
Never sue starting aid fluids as they may cause explo-
sions.
Exhaust gas is toxic. When starting the engine in con-
fined spaces, be particularly careful to ensure good
ventilation.

NOTICE
Do not crank the starting motor continuously for more
than 20 seconds. If the engine does not start, wait for at
least 2 minutes, then repeat the procedure from Step 2.
Before starting the engine, check that the fuel control
dial is at the low idling (MIN) position.
On this machine, to protect the turbocharger, a turbo
protect function is provided. In cold weather, even if
fuel control dial (1) is operated immediately after start-
ing the engine, the engine speed may not change for
several seconds.
If the fuel control dial is at the FULL position, the
engine will accelerate suddenly and cause damage to
the engine parts, so set it to an intermediate or low
speed position.

1. Turn fuel control dial (1) to the center position between MIN
and MAX position.

Mid-range
Speed
MIN
Low idling

3-72
OPERATION OPERATION

2. Turn the key of starting switch (2) to the ON position.

3. Check that preheating pilot lamp (3) on the monitor panel is

lighted up.

4. Keep this condition until preheating pilot lamp (3) goes off.

5. When preheating pilot lamp (3) goes off, turn the key of
starting switch (2) to the START position to crank the
engine.
The time that preheating pilot lamp (3) stays on changes
according to the ambient temperature as shown in the table
below.

Ambient temperature Preheat time

-5°C to -10°C 20 to 27 seconds

-10°C to -20°C 27 to 40 seconds

-20°C to -30°C 40 seconds

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

(2). The key will return automatically to the ON position.

REMARK

3-73
OPERATION OPERATION

Immediately after starting the engine, run at idling. While running the engine, release the decelerator
pedal and do not operate the work equipment.
Guideline for idling time
Cold weather: At least 15 seconds
1st start after changing engine oil or engine oil filter: 20 seconds

7. When the engine rotation stabilizes, return to the low idling (MIN) position of fuel control dial (1) and then carry
out the warming-up operation.
REMARK
Regardless of the ambient temperature, if the key in the starting switch (2) is turned from the OFF posi-
tion to the left, preheating pilot lamp (3) will light up and preheating will start. (Preheating continues
while the starting switch is being held at the left.)
For details of the preheating time, see the table in Step 5.
During the preheating operation, preheating pilot lamp (3) lights up to show that preheating is being
carried out.
If the engine does not start with the above operation, wait for at least 2 minutes, and repeat the proce-
dure in Steps 3 and 4.

REMARK
The turbo protect function is a function to protect the turbocharger. It keeps the engine speed below
1000 rpm for a set time after the engine is started even if the pedal is fully depressed.
The basic function acts to cancel the actuation of the turbo protect function when the engine oil pres-
sure rises. The settings for the maximum actuation time are as shown below. When the turbo protect
function is being actuated, the engine speed does not change even when the fuel control dial is oper-
ated.

Cooling water temperature Turbo protect time (sec.)

Above 10°C 0

10 to -30°C Change 0 to 20

below -30°C 20

3-74
OPERATION OPERATION

OPERATIONS AND CHECKS AFTER STARTING ENGINE 0.

WARNING
If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position.
If the work equipment is operated without warming the machine up sufficiently, the response of the
work equipment to the movement of the control lever will be slow, and the work equipment may not
move as the operator desires, so always carry out the warming-up operation. Particularly in cold
areas, be sure to carry out the warming-up operation fully.

BREAKING IN THE MACHINE 0.

CAUTION
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 operations, follow the precautions described in this manual.

Run the engine at idling for 15 seconds after starting it. During this time, do not operate the control levers or
fuel control dial.
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.

NORMAL OPERATION 0.
NOTICE
Do not carry out operations or operate the levers sud-
denly when the hydraulic oil is still at low temperature.
Always carry out the warming-up operation until the
hydraulic oil temperature monitor displays the green
range. This will help to extend the machine life.
Do not accelerate the engine suddenly before the
warming-up operation is completed.
Do not run the engine at low idling or high idling contin-
uously for more than 20 minutes. This will cause leak-
age of oil from the turbocharger oil supply piping.
If it is necessary to run the engine at idling, apply a load
from time to time or run the engine at a mid-range
speed.
If engine oil pressure caution lamp (3) flashes or the
buzzer sounds intermittently, stop the engine and
check for the cause.

3-75
OPERATION OPERATION

1. Turn fuel control dial (1) to the center position between

LOW IDLING (MIN) and HIGH IDLING (MAX) and run the
engine at medium speed for about 5 minutes with no load.
2. After warm-up run is completed, check gauges and caution
lamps for proper operation. If any abnormality is found,
repair it. Mid-range
Continue to run the engine at light load until engine water speed
temperature gauge indicator (2) falls within the green range
(B). MIN
(A): White range Low idling
(B): Green range
(C): Red range

3. Check that there is no abnormal exhaust gas color, noise or vibration. If any abnormality is found, contact your
Komatsu distributor.

3-76
OPERATION OPERATION

IN COLD AREAS 0.
1. Turn fuel control dial (1) to the center position between
LOW IDLING (MIN) and HIGH IDLING (MAX) and run the
engine at medium speed for about 10 minutes with no load.

Mid-range
speed

MIN
Low idling

2. Operate blade control lever (4) to the RAISE position, then

keep the blade raised to the maximum height and continue
to relieve the circuit for 10 minutes.
3. Finally, operate blade control lever (3) and ripper control Raise
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.
4. 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 (2) falls within the green range
(B).
(A): White range
(B): Green range
(C): Red range

REMARK
If the oil temperature in the power train is not raised prop-
erly, it will take longer to accelerate to the maximum
speed.

5. Check that there is no abnormal exhaust gas color, noise or vibration. If any abnormality is found, contact your
Komatsu distributor.

3-77
OPERATION OPERATION

STOPPING ENGINE 0.
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 medium speed to allow it to cool gradu-
ally, then stop it.

1. Place fuel control dial (1) in the low idling (MIN) position and
run the engine at low idling speed for about 5 minutes to
allow it to gradually cool down.

MIN
Low idling

2. Place fuel control lever (1) in the engine stop position and
stop the engine.

3. Remove the key of starting switch (2).

CHECK AFTER STOPPING ENGINE 0.

1. Walk around the machine and check the work equipment, machine exterior, 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 affixed to the undercarriage.

3-78
OPERATION OPERATION

MOVING MACHINE OFF 0.

WARNING
When moving the machine off, check that the area
around the machine is safe, and sound the horn
before moving.
Do not allow anyone to enter the area around the
machine.
There is a blind spot at the rear of the machine, so be
particularly careful when traveling in reverse.
When moving the machine off on a slope, always keep
brake pedal (8) depressed even after releasing parking
lever (1).
When starting the machine off up a steep slope, turn
fuel control dial (5) fully to run the engine at full
speed, and keep brake pedal (8) and deceleration
pedal (6) depressed. Then operate steering, direc-
tional, and gearshift lever (4) from the N position to
the direction of travel and release brake pedal (8)
slowly. When the travel speed rises, release decelera-
tion pedal (6) slowly.

1. Set parking lever (1) to the FREE position

Free
Lock
2. Set safety lever (2) for blade control lever (3) and ripper
control lever (4) to the FREE position.

Free

Lock

3. Operate blade control lever (3) and ripper control lever (4)
to the RAISE position, raise the blade 40 - 50 cm from the Float Lower
ground, and raise the ripper to the maximum height. Hold

Raise

Raise

Lower

3-79
OPERATION OPERATION

4. Turn fuel control dial (5) to the full speed (MAX) position,
raise the engine speed, and fully depress decelerator pedal
(6). Full speed
MAX

5. Move joystick (7) to the F (FORWARD) or R (REVERSE)

position, gradually release the decelerator pedal (6) and
allow the machine to move off

3-80
OPERATION OPERATION

STOPPING MACHINE 0.

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 nec-
essary to park the machine on a slope, place the park-
ing lever (1) in the LOCK position and insert blocks
underneath the track shoes. As an additional safety
measure, thrust the blade into the ground.
If the work equipment control lever is touched by acci-
dent, the work equipment may move suddenly, and
this may lead to a serious accident. before leaving the
operator's seat, always operate the safety lever (2) to
place it securely at the LOCK position.

1. Depress brake pedal (3) to apply the brake.

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 (4) to reduce the
engine speed and travel speed before depressing the
brake.

2. Set joystick (5) at the neutral position.

3-81
OPERATION OPERATION

SHIFTING GEAR 0.
The machine does not have to be stopped to shift gears.
1. Move joystick (1) to the desired gear position to shift gears.

GEAR SHIFTING 0.
When the joystick is at the FORWARD or REVERSE posi-
tion and switch (a) or switch (b) is pushed, the transmission
speed will change.
UP switch (a): Each time the switch is pressed, the trans-
mission will shift up one speed.
DOWN switch (b): Each time the switch is pressed, the
transmission will shift down one speed.

When the lever is operated forward (to set to FORWARD) from the N position, the transmission shifts to F1.
If the UP switch is pressed once when the transmission is in F1, the transmission shifts to F2.
If the UP switch is pressed once when the transmission is in F2, the transmission shifts to F3.
If the DOWN switch is pressed once when the transmission is in F3, the transmission shifts to F2.
If the DOWN switch is pressed once when the transmission is in F2, the transmission shifts to F1.
When the lever is operated rear (to set to REVERSE) from the N position, the transmission shifts to F1.
If the UP switch is pressed once when the transmission is in R1, the transmission shifts to R2.
If the UP switch is pressed once when the transmission is in R2, the transmission shifts to R3.
If the DOWN switch is pressed once when the transmission is in R3, the transmission shifts to R2.
If the DOWN switch is pressed once when the transmission is in R2, the transmission shifts to R1,

For details of the maximum speed at each speed range, see SPECIFICATIONS ( 5-2 ).

REMARK
The speed range in use is displayed on the panel display
according to the gearshift operation.
For example:
Neutral: N is displayed on the display panel A (2)
FORWARD 2nd: F2 is displayed on the display panel A (2)
REVERSE 3rd: R3 is displayed on the display panel A (2)
When the parking lever is locked, P is displayed.

3-82
OPERATION OPERATION

GEARSHIFTING OPERATION USING PRESET MODE FUNCTION 0.

Shift mode selection means that the selected speed range is displayed at the N position before starting.
This can be used when preset mode switch (3) is turned to the ON position.
When the joystick is at the N position, if UP switch (a) or
DOWN switch (b) is pressed, the shift mode selection can
be carried out.

F1-R1 mode
F1-R2 mode
F2-R2 mode

The selected shift mode is displayed on display panel B

(multi-information) of the monitor panel.

Shift operation when [F1-R1] mode is set

When the preset mode switch is turned ON, the [F1-R1]
mode is set by default.
After that, if the steering, directional, and speed lever is
operated forward (forward travel operation), the transmis-
sion is shifted to F1.
If it is operated back (reverse travel operation), the trans-
mission is shifted to R1.

Shift operation when [F1-R2] mode is set

When the steering, directional, and speed lever is at the N position, if the up switch is pressed once, the mode
is set to [F1-R2] mode. After that, if the steering, directional, and speed lever is operated forward (forward
travel operation), the transmis-
sion is shifted to F1. If it is operated back (reverse travel operation), the transmission is shifted to R2.

Shift operation when [F2-R2] mode is set

When the steering, directional, and speed lever is at the N position, if the up switch is pressed twice, the mode
is set to [F2-R2] mode. After that, if the steering, directional, and speed lever is operated forward (forward
travel operation), the trans-
mission is shifted to F2. If it is operated back (reverse travel operation), the transmission is shifted to R2.

REMARK
Even when the mode is set to [F1-R1] mode, [F1-R2] mode, or [F2-R2] mode, it is possible to switch to the
desired speed range simply by operating the up switch or down switch.
For example, when the mode is set to [F1-R2] mode, if the steering, directional, and speed lever is oper-
ated forward (forward travel operation), the transmission is shifted to F1, but if up switch (a) is pressed
once with the lever pushed forward, the
transmission is shifted to F2; if it is pressed twice, the transmission is shifted to F3. If the down switch (b)
is pressed once when the transmission is in F3, the transmission is shifted to F2; if it is pressed twice, the
transmission is shifted to F1.
If the steering, directional, and speed lever is operated back (reverse travel operation), the transmission is
shifted to R2, but if up switch (a) is pressed once with the lever pulled back, the transmission is shifted to
R3; if down switch (b) is pressed
once, the transmission is shifted to R1.
However, the mode remains in the [F1-R2] mode. If the steering, directional, and speed lever is returned
to the N position and operated forward again (forward travel operation), the transmission is shifted to F1.
If it is operated back (reverse travel
operation), the transmission is shifted to R2.

REMARK
When the preset mode switch is turned ON, the [F1-R1] mode is set by default.

3-83
OPERATION OPERATION

AUTO SHIFT DOWN OPERATION 0.

If the travel speed drops due to the load conditions when trav-
eling, this function automatically shifts the transmission is to a
lower speed range. This is actuated by turning auto shift down
switch (4) on the instrument panel at the front of the opera-
tor's compartment to the (b) (ON) position .

OFF position (a): Canceling function

ON position (b): Automatically shifted down to lower speed
range

The transmission is automatically shifted down F2→ F1, F3 →

F2, R2 → R1, R3 → R2.

REMARK
For safety reasons, during auto shift down, the trans-
mission is prevented from shifting up.

If it is desired to shift up, use manual control and press the

UP button on the steering, directional, and gearshift lever.

SHIFTING BETWEEN FOEWARD AND REVERSE 0.

WARNING
When switching between FORWARD and REVERSE,
check first that the direction of travel is safe.

CAUTION
There is no need to stop the machine even when switch-
ing 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.

3-84
OPERATION OPERATION

1. Depress decelerator pedal (1) and reduce the engine

speed.

2. Return joystick (2) to the neutral position, reduce the speed,

then depress brake pedal (3) and stop the machine.

3. After depressing decelerator pedal (1), move joystick (2) to

the desired position.

4. Release decelerator pedal (1) and raise the engine speed.

REMARK
When the joystick is placed in REVERSE, the backup
alarm will sound.

3-85
OPERATION OPERATION

STEERING MACHINE 0.
WARNING
Avoid as much as possible turning the machine on a slope.
The machine will tend to slip sideways. Particular care should be taken on soft or clay land.
Never make a pivot turn at high speed.

NORMAL TURNING 0.
To turn the machine while traveling, incline joystick (1) in the
direction to turn.

TURNING GRADUALLY TO LEFT WHILE TRAVELING FORWARD 0.

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.

When turning gradually to the right, push the joystick forward,

and move it partially to the right.
Do the same when traveling in reverse.

3-86
OPERATION OPERATION

COUNTERROTATION TURNS TO LEFT WHEN TRAVELING FORWARD 0.

NOTICE
When carrying out a counterrotation turn, if the load is not
equal on the left and right sides, the machine may carry
out a pivot turn, so check the ground conditions and be
careful not to hit any obstacles.

With joystick (1) at the N position, operate the lever partially to

the left (L). The left and right tracks will rotate in opposite direc-
tions, and the machine will make a slow counterrotation turn. If
the lever is operated further, the speed of the counterrotation
turn will increase.

REMARK
When making a right counterrotation turn, operate the joy-
stick (1) to the right (R) in the same way.

TURNING WHILE DESCENDING A SLOPE 0.

TURNING GRADUALLY TO LEFT WHILE TRAVELING FORWARD 0.
If the joystick (1) is pushed forward and moved partially to the
left (L), the machine turns gradually to the left.

REMARK
When making gradual turns to the right, push the joystick
(1) forward, and move it partially to the right.
Do the same when traveling in reverse.

3-87
OPERATION OPERATION

PRECAUTIONS FOR OPERATION 0.

PAY ATTENTION TO GAUGES 0.
When the red range lights on the power train oil temperature gauge while operating, reduce load and wait for low-
ering of temperature.

PERMISSIBLE WATER DEPTH 0.

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. Permissible
water depth

PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS 0.

METHOD OF USING DECELERATOR PEDAL 0.
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 0.

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 (R1 or F2).

BRAKING WHEN TRAVELING DOWNHILL 0.

While descending a slope using the engine as a brake, also apply the brakes.
Failure to brake may result in overrunning, causing engine trouble.

PRECAUTIONS ON SLOPE 0.
BE CAREFUL OF FUEL LEVEL 0.
If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the
angle of the machine or the swaying of the machine. If this makes the engine stop, the braking effect will be
reduced, so be careful not to let the fuel level in the fuel tank become too low.

BE CAREFUL OF OIL LEVEL 0.

When operating machine on sloped areas of more than 20°, fill every place with oil to H level.

PRECAUTIONS WHEN ENGINE STOPS ON SLOPE 0.

If the engine stops while working or traveling on a hill, immediately depress the brake pedal to bring the machine to
a complete stop.

METHOD OF USING BRAKES 0.

The following actions cause premature damage to the brakes, so avoid such operations.
Using emergency brake at full speed
Using brake with engine running at full speed in first gear (F1, R1) (Machine stall condition)

REMARK
Always depress the decelerator pedal to lower the engine speed before actuating the brakes.

3-88
OPERATION OPERATION

PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS 0.

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

IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL

OBSTRUCT THE VIEW 0.
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.

PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY 0.

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.

PARKING MACHINE 0.

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 nec-
essary to park the machine on a slope, place the park-
ing lever (4) in the LOCK position and insert blocks
underneath the track shoes. As an additional safety
measure, thrust the blade into the ground.
If the work equipment control lever is touched by acci-
dent, the work equipment may move suddenly, and
this may lead to a serious accident. Before leaving the
operator's seat, always operate the safety lever (7) to
place it securely at the LOCK position.

3-89
OPERATION OPERATION

1. Depress brake pedal (1) 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 (2) to reduce the
engine speed and travel speed before depressing the
brake.

2. Place joystick (3) at the neutral position and set the speed
range to 1st.

3. Operate parking lever (4) to lock the brakes.

Free
Lock
4. Operate blade control lever (5) and ripper control lever (6)
to the LOWER position, and lower the blade and ripper to Float Lower
the ground. Hold
5. Set blade control lever (5) and ripper control lever (6) to the
HOLD position. Raise
Hold
Raise

Lower

6. Set safety lever (7) for blade control lever (5) and ripper
control lever (6) to the FREE position.

Free

Lock

3-90
OPERATION OPERATION

CHECK AFTER FINISHING WORK 0.

Use the meters and caution lamps to check the engine water
temperature, engine oil pressure, fuel level and power train oil
temperature.

LOCKING 0.
To prevent vandalism, there are locks at the following places.
Places that can be locked with the starting switch key.
Right and left engine side cover (1)
(left side: 2 places, right side: 2 places)
Cab door opener (3)
Cap with lock (4)
Radiator cap (if equipped)
Fuel tank cap (if equipped)
Hydraulic oil tank cap
Battery inspection cover(2)
Rear cover (5)

3-91
OPERATION OPERATION

WORK POSSIBLE USING BULLDOZER 0.

In addition to the following, it is possible to further increase the range of applications by using various attachments.

DOZING 0.
A bulldozer digs and transports dirt in a forward direction slope
excavation can always be most effectively carried out by pro-
ceeding 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.

CUTTING INTO HARD OR FROZEN GROUND OR DITCHING 0.

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 effi-
ciency.

FELLING TREES, REMOVING STUMPS 0.

NOTICE
Do not up root trees or stumps or fell trees by angling or
tilting the blade.

For trees with a diameter of 10 to 30 cm, 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.

PUSHER OPERATIONS 0.
When carrying out pusher operations, always install a
pusher plate.
When approaching the other machine, depress the deceler-
ator pedal to reduce the engine speed and approach slowly.
After coming into contact, raise the travel speed slowly and
push with full power.

3-92
OPERATION OPERATION

SMOOTHING 0.
NOTICE
Avoid smoothing on rocky or stony ground. It can damage
the blade.

When finishing the ground surface to a smooth finish after dig-

ging or filling operations, keep a full load of soil in the blade and
operate the blade up or down in small movements while travel-
ing 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.

3-93
OPERATION OPERATION

ADJUSTING POSTURE OF WORK EQUIPMENT 0.

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.

BLADE ADJUSTMENT 0.
TILTING THE TILTDOZER 0.
NOTICE
The maximum tilt is 735 mm for the EX specification machine and 500 mm for the PX specification
machine.
When tilting, make sure that it does not exceed 735 mm for the EX specification machine or 500 mm for the
PX specification machine.
If the maximum tilt is exceeded, excessive force will be brought to bear on all parts, and this will damage
the machine.

If the blade control lever is operated, the following tilt amount

can be obtained.
Right side: 410 mm or more
Left side: 410 mm or more
If more tilt is required, do as follows.
Use bar handle (2) installed to the left brace to turn brace (1)
and change length (L) of the brace. This makes it possible to
obtain a maximum tilt of 735 mm for the EX specification
machine and 500 mm for the PX specification machine.
Standard distance between joints (L): 1287 mm

ADJUSTING SHIM IN BLADE CYLINDER CAP 0.

Set the standard shim adjustment in the blade cylinder cap to 4
mm.
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.

3-94
OPERATION OPERATION

ADJUSTING DIGGING ANGLE 0.

(PX Specifications)
It is possible to change the digging angle (A) of the blade by
removing cap (1) and bolt (2) installed between the blade and
tilt cylinder or brace (3), or replacing with optional parts.
This is extremely effective in improving the earth rolling func-
tion of the blade on soft ground without using the tilt cylinder to
change the left and right tilt.

1. When replacing with optional cap (1) and bolts (2)

Digging angle (A): 55° -> 52.5°
Part numbers for replacement parts
Cap (1): 154-929-3210 (2 caps/machine)
Bolt (2): 01011-82420 (8 bolts/machine)

2. When removing cap (1) installed to standard machine

Digging angle (A): 55° -> 50.5°
Prepare the following parts for bolts (2) and replace.
Bolt (2): 01010-82490 (8 bolts/machine)

REMARK
It is possible to change digging angle (A) of the blade by a range of ±5° by changing the length (L) of the
brace and tilt cylinder.

However, the more the digging angle is changed, the more the change becomes in the amount of tilt on
the left and right sides provided by the tilt cylinder. 0.
ADJUSTING BRACE 0.

WARNING
If maintenance is carried out with the engine running,
always have one worker sitting in the operator's seat
while another worker carries out the maintenance. Both
workers must mutually confirm the safety during the oper-
ation.
Brace handle
300-400 mm
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.

When extending the brace

It is easy to carry out the adjustment if the blade is set on top of
a block and the brace handle is turned.

3-95
OPERATION OPERATION

REMARK
When operated in this way, the blade is tilted, so the han-
dle 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 0.
Adjust the thickness of shim so that the ball joint play (4 points)
in the axial direction (shown by the arrow) does not exceed 1
mm.

1. Remove shim (1) and tighten bolts (2) to eliminate the ball
joint play.
2. Measure clearance “A“ and remove bolts (2).
3. Adjust the thickness of shim (1) to A + 0.5-1 mm, then
tighten bolt (2)..
4. Confirm that ball joint can move smoothly after tightening
bolts.

ADJUSTING RIPPER 0.
ADJUSTING DIGGING DEPTH 0.
Mounting pin holes are provided in the shank and these are used according to the desired digging depth. For nor-
mal use, use the bottom hole, and when particularly deep digging is needed, use the top hole.
1. Place a pointed object on the tip of pin (1), then hit with a
hammer to remove from the opposite side.
2. Remove pin (2) and change the position of the shank hole.
3. Insert pin (1) partially by hand then knock it in with a ham-
mer.
The pin is made of one piece, so insert it partially by
hand then knock it in with a hammer.

3-96
OPERATION OPERATION

REPLACING POINT AND PROTECTOR 0.

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 by
hand, then knock it in fully with a hammer.

3-97
OPERATION OPERATION

TIPS FOR LONGER UNDERCARRIAGE LIFE 0.

Undercarriage life greatly varies depending on operation method, inspection and maintenance. For most efficient
operation, keep the following point in mind.

OPERATION METHOD 0.
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. If shoe slipping occurs, reduce load to the blade until slip-
ping stops.
Avoid sudden starts, acceleration or stops, unnecessarily high speeds and sharp turns.
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 to prevent machine from riding over them while operating.
On a slope, operate the machine parallel to the inclination of
the slope. Do not operate across the slope. Also when stop-
ping the machine on a slope, the machine should face
toward the top of the slope.
When ground inclines to left or right during digging opera-
tion, 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.

INSPECTION AND ADJUSTING 0.

Properly adjust track tension.
Tension should be measured at clearance (A) shown in the
diagram - usually 20 to 30 mm at this point. For rocky ter-
rain, tighten tracks slightly. In clay or sandy areas, slightly
loosen them. (For inspection and adjustment procedures,
refer to “CHECK TRACK TENSION ( 4-24 )“).
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 (B) increases, idler may develop
side motion and tracks may come off. (For inspection and
adjustment procedures, refer to “ADJUST IDLER CLEAR-
ANCE ( 4-26 )“.

3-98
OPERATION OPERATION

INSPECTION AND REPAIR 0.

Frequent inspection and prompt repair will reduce repair costs.
The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per-
form periodical inspection and contact the Komatsu distributor in your area when machine has approached repair-
able limits and reversing limits.

MEASURING HEIGHT OF GROUSER 0.

After taking up slack in track shoes, measure height at cen-
ter of shoe as shown below.
Standard height (h): 72 mm
Repair limits: 25 mm

MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 0.

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 ) x 2
Standard size (A): 222 mm (Single roller)
Repair limits: 182 mm (Double roller)
182 mm

3-99
TRANSPORTATION OPERATION

TRANSPORTATION 0.
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.

TRANSPORTATION PROCEDURE 0.
A trailer should be used for transporting the machine.

LOADING, UNLOADING WORK 0.

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.

When loading or unloading, always use ramps or a platform and carry out the operations as follows.
1. 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.
2. Set the machine in line with the ramps, then load or unload Ramp
the machine at slow travel.
3. Load the machine correctly in the specified position on the
trailer. Blocks
Distance
between
ramps

PRECAUTIONS FOR LOADING 0.

After placing the machine on the specified position of the trailer, secure it according to the following procedure.
1. Lower the work equipment slowly.
2. Lock each control lever with the safety lock lever securely.
3. Set the parking lever to the LOCK position.
4. Turn the starting switch to the OFF position, stop the engine, then remove the key.
5. Lock the cab door, left and right engine side covers, and the battery inspection cover.
6. Put blocks under both ends of the tracks to prevent the machine from moving during transportation, and tie the
machine down securely with chains or wire rope of suitable strength.
Be particularly careful to fix the machine in position securely so that it does not slip to the side.

3-100
OPERATION TRANSPORTATION

METHOD OF LIFTING MACHINE 0.

WARNING
Never carry out the lifting operation with any person on the machine.
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 machine,pay careful attention to the center of gravity to maintain the balance.

When lifting the machine, carry out the operation on flat ground
as follows.
1. Stop the engine and be sure to set the parking lever to the
LOCK position.
2. Set the lifting position for the machine as shown in the dia-
gram on the right.

NOTICE
The lifting procedure applies to machines with standard
specifications.
The method of lifting differs according to the attachments
and options actually installed. In such cases, please con-
tact your Komatsu distributor for information.

For details of the weight, see “SPECIFICATIONS ( 5-2 )“.

3-101
TRANSPORTATION OPERATION

PRECAUTIONS FOR TRANSPORTATION 0.

WARNING Block Block

Determine the route for transporting the machine by tak-

ing into account the width, height and weight of the
machine.

Obey all state and local laws governing the weight, width and
length of a load. Observe all regulations governing wide loads.

TRAVELING ON ROADS 0.
When travelling paved roads, use flat shoes to protect their surface.
Even when travelling a short distance, always place boards to protect the road surface.

REMARK
Note that the asphalt road becomes soft in summer.

REMOVAL OF CAB 0.
(Machines equipped with cab)
If it is necessary to remove the cab for transportation, discon-
nect the washer hoses, cab wiring, and washer motor wiring
before removing the cab.
1. Pull the grommet portion in towards the cab from the hole in
the machine cover, then remove.
2. Disconnect 4 washer hoses and the wiring (single wires x 2,
4-pin plug x 1) from the socket.
After removing, cover the washer hoses with a vinyl bag
to prevent any dirt or dust from entering.
Before removing the cab, measure the clearance
between the cab and each lever (joystick and blade con-
trol lever, etc.). Note the measurements to use as a stan-
dard when installing the cab again. A
B
C
A Red - right door D
B Blue - left door
E
C Black - rear window

D Colorless - front window F

E Washer tube

F From fuse box. Red (Back up power source)

3-102
OPERATION TRANSPORTATION

INSTALLATION OF CAB 0.
(Machines equipped with cab)
Install the cab parts in the opposite order to removal.
Connect all parts that were disconnected.
Install the cab mounting bolts as follows.
1. 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 (A) - (U).
Do not screw the bolts in fully. Screw them in 3 or 4 turns.
3. Tighten the bolts in holes (N) - (U) fully.
Tighten in the order (N), (U), (Q), (R), (O), (T), (P), (S).
4. Tighten the bolts, (A) to (M), completely.

If there are any unclear points about removing or installing

the cab, please contact your Komatsu distributor.

INSTALLATION OF ROPS 0.
Tighten the bolts securely to the following tightening torque.
All 12 bolts : 824 - 1030 N·m (84 - 105 kgf·m)

3-103
COLD WEATHER OPERATION OPERATION

COLD WEATHER OPERATION 0.

PRECAUTIONS FOR LOW TEMPERATURE 0.
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as fol-
lows.

FUEL AND LUBRICANTS 0.

Change to oil with low viscosity for all components. For details of the specified visicosity, see “USE OF FUEL,
COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ( 4-9 )“.

COOLANT 0.

WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your
eyes or on your skin, wash it off with large amount of fresh water and see a doctor at once.
When changing the coolant or when handling coolant containing antifreeze that has been drained
when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let
it flow into drainage ditches or spray it on to the ground surface.
Antifreeze is flammable, so do not bring any flame close. Do not smoke when handling antifreeze.

NOTICE
Never use methanol, ethanol or propanol based antifreeze.
Avoid using any leak-preventing agent, regardless if it is sold separately or in antifreeze.
Do not mix one antifreeze with a different brand.

For details of the antifreeze mixture when changing the coolant, see “CLEAN INSIDE OF COOLING SYSTEM ( 4-
19 )“.
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the stan-
dard 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 infor-
mation.
Standard requirements for permanent antifreeze
SAE J1034
FEDERAL STANDARD O-A-548D

REMARK
In areas where permanent antifreeze is not available, it is possible to use antifreeze whose main compo-
nent is ethylene glycol and does not contain any corrosion inhibitor. (Such antifreeze can be used for the
winter season only.) However, in such a case, the cooling water must be changed twice a year (spring and
fall), so use permanent antifreeze when possible.

BATTERY 0.

WARNING
The battery generates flammable gas, so do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount
of water and consult a doctor.
Battery electrolyte dissolves paint. If it gets on to the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is danger that the battery may explode.
Battery electrolyte is toxic, so do not let it flow into drainage ditches or spray it on to the ground sur-
face.

3-104
OPERATION COLD WEATHER OPERATION

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

Electrolyte Temperature (°C)

Charging Rate (%) 20 0 -10 -20

100 1.28 1.29 1.30 1.31

90 1.26 1.27 1.28 1.29

80 1.24 1.25 1.26 1.27

75 1.23 1.24 1.25 1.26

REMARK
When adding distilled water in cold weather, add it before starting operations in the morning to prevent
the electrolyte from freezing.

AFTER COMPLETION OF WORK 0.

WARNING
Raising the track and rotating it in order to remove dirt from the undercarriage involves danger, so do not
come close to the track when it is rotating.

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.
When operating in mud or water, remove the water from the undercarriage to extend the life of the undercar-
riage.
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.

AFTER COLD WEATHER 0.

When season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all parts with oil of the viscosity specified.
For details, see “USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
( 4-9 )“.
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 thoroughly, and fill with fresh soft water.
When it is unnecessary to use the automatic starting aid (APS) (When the ambient temperature is above 15°C),
Always keep the fuel valve closed.

3-105
LONG-TERM STORAGE OPERATION

LONG-TERM STORAGE 0.
BEFORE STORAGE 0.
When putting the machine in storage for more than one month, do as follows.
After every part is washed and dried, the machine shall be housed in a dry building. In case it is unavoidable to
leave it outdoors, park the machine on flat ground free from flooding or other disaster and cover it with canvas
etc.
Completely fill the fuel tank, lubricate and change the oil before storage.
Apply a thin coat of grease to metal surface of the hydraulic piston rods and the idler adjusting rods.
Disconnect the negative terminals of the battery and cover it, or remove it from the machine and store it sepa-
rately.
Komatsu genuine Super Coolant (AF-ACL) is added to the cooling water, so there is no need to change the
density for temperatures down to -10°C.
If the temperature goes below -10°C, adjust the density. For details, see “CLEAN INSIDE OF COOLING SYS-
TEM ( 4-19 )“.
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.

DURING STORAGE 0.
WARNING
If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors,
open the doors and windows to improve ventilation and prevent gas poisoning.

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, wipe off the grease on the hydraulic piston rod.

AFTER STORAGE 0.
NOTICE
If the machine is to be used when the monthly rust prevention operation has not been carried out, please
contact your Komatsu distributor.

When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease to all places.
When a machine is stored for a long period, moisture in the air will get into the oil. Check the oil before and
after starting the engine. If there is water in the oil, change the oil.

3-106
OPERATION TROUBLESHOOTING

TROUBLESHOOTING 0.
AFTER RUNNING OUT OF FUEL 0.
WARNING
When air bleed plug (2) at the top of the fuel filter head or supply pump air breather (4) are removed, the
system is still under pressure, so fuel may spurt out. Loosen these parts slowly before opening them.

When starting after running out of fuel, fill the filter cartridge with fuel and bleed the air from the fuel system before
starting.

PROCEDURE FOR BLEEDING AIR 0.

1. Remove the fuel filter cartridge, fill the filter case with fuel, then install again.

NOTICE
The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzle, so problems may be caused by dust or dirt getting in. When
carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry
of dirt. If dirt is stuck to any part, use fuel to wash it off completely.
If no clean fuel is available, bleed the air with priming pump (3) without removing the fuel cartridge.

NOTICE
When filling with fuel, use clean fuel and be careful not
to let any dust or dirt get in. Portion (B) at the center is
the clean side, so be particularly careful not to let any
dust or dirt get in.
When adding fuel, always add from small hole (A) at
eight places on the dirty side.

2. Loosen air bleed plug (2) at the top of the fuel filter head
and open fuel supply valve (1) at the bottom of the fuel tank.
3. Loosen the knob of priming pump (3), pump the knob, and
check that fuel comes out from air bleed plug (2).
After checking, tighten the plug.
Tightening torque: 7.8 to 9.8 N·m (0.8 to 1 kgf·m)

4. Push the knob of priming pump (3) in and tighten it.

5. If the air is not bled properly, return to Step 3 and bleed the air again.
6. For normal starting operations, turn the key in the starting switch to the START position to start the engine.

3-107
TROUBLESHOOTING OPERATION

METHOD OF TOWING MACHINE 0.

WARNING
Be sure to use a wire rope sufficiently strong for the
towing weight.
When using the towing hook, be sure to use a
shackle.
Set the wire rope horizontally and align it with the
track frame.
Tow the machine slowly.

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.

NOTICE
Permissible load for towing hook: 21,800 kgf (213,780 N)
Always carry out towing operations within the specified
range for the permissible load.

3-108
OPERATION TROUBLESHOOTING

IF BATTERY IS DISCHARGED 0.

WARNING When removing

disconnect the
When checking or handling the battery, stop the cable from the
engine and turn the starting key to the OFF position ground terminal
before starting. first
The battery generates hydrogen gas, so there is dan-
ger 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 When installing,
or on your skin, wash it immediately off with large connect the cable
amounts of water. If it gets in your eyes, wash it out to the positive
with fresh water, and consult a doctor. (+) terminal first.
Wear protective glasses and rubber gloves when han-
dling the battery.
When removing the battery, first disconnect the cable
for the ground (normally, from the negative (-) termi-
nal). When installing, install the positive (+) terminal
first. If a tool touches the cable connecting the posi-
tive 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.
Check the positive (+) and negative (-) terminals care-
fully when removing or installing.

STARTING ENGINE WITH BOOSTER CABLE 0.

When starting the engine with a booster cable, do as follows.

REMOVAL AND INSTALLATION OF BATTERY 0.

1. Open battery cover (1).
2. Before removing the battery, remove the ground cable (nor-
mally 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: 9.8 to 19.6 N·m (1 to 2 kgf·m)
4. Close battery cover (1).

3-109
TROUBLESHOOTING OPERATION

PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE 0.

WARNING
When connecting the cables, never contact the posi-
tive (+) and negative (-) terminals.
When starting the engine with a booster cable, always
wear safety glasses and rubber gloves.
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.
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.
When disconnecting the booster cable, take care not
to bring the clips in contact with each other or with the
machine body.

NOTICE
The size of the booster cable and clip should be suitable for the battery size.
The battery of the normal machine must be the same capacity as that of the engine to be started.
Check the cables and clips for damage or corrosion.
Make sure that the cables and clips are firmly connected.
Check that the safety lock levers and parking brake levers of both machines are in the LOCK position.
Check that each lever is in the NEUTRAL position.

CONNECTING THE BOOSTER CABLES 0.

Keep the starting switch of the normal machine and problem machine both 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.
2. Connect one clip of booster cable (A) to the positive (+) ter-
minal of the problem machine.
3. Connect the other clip of booster cable (A) to the positive
(+) terminal of the normal machine.
4. Connect one clip of booster cable (B) to the negative (-) ter-
minal of the normal machine. Battery of the Battery of the
normal machine problem machine
5. Connect the other clip of booster cable (B) to the engine
block of the problem machine.
Engine block of the problem machine

STARTING THE ENGINE 0.

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

3-110
OPERATION TROUBLESHOOTING

DISCONNECTING THE BOOSTER CABLES 0.

After the engine has started, disconnect the booster cables in the reverse of the order in which they were con-
nected.
1. Remove one clip of booster cable (B) from the engine block
of the problem machine.
2. Remove the other clip of booster cable (B) from the nega-
tive (-) terminal of the normal machine.
3. Remove one clip of booster cable (A) from the positive (+)
terminal of the normal machine.
4. Remove the other clip of booster cable (A) from the positive
(+) terminal of the problem machine. Battery of the Battery of the
normal machine problem machine

Engine block of the

problem machine

3-111
TROUBLESHOOTING OPERATION

OTHER TROUBLE 0.
ELECTRICAL SYSTEM 0.
( ): 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.

Problem Main cause Remedy

Lamp does not glow brightly even •Defective wiring (•Check, repair loose terminals,
when the engine runs at high disconnections
speed Check fuses and diodes in fuse
box)
Lamp flickers while engine is run- •Defective adjustment of fan belt •Adjust fan belt tension
ning tension For details, see EVERY 250
HOURS SERVICE

Charge lamp doe not go out even •Defective alternator (•Replace)

whhen engine is running •Defective wiring (•Check, repair
Check fuse, diode in fuse box)

Abnormal noise is generated from •Defective alternator (•Replace)

alternator

Starting motor does not turn when •Defective wiring (•Check, repair)
starting switch is turned to ON •Insufficient battery charge •Charge

Pinion of starting motor keeps •Insufficient battery charge •Charge

going in and out

Starting motor turns engine slug- •Insufficient battery charge •Charge

gishly •Defective starting motor (•Replace)

Starting motor disengages before •Defective wiring (•Check, repair)

engine starts •Insufficient battery charge •Charge

Preheating monitor lamp does not •Defective wiring (•Check, repair)

light up •Defective timer (•Replace)
(When the temperature of the •Defective monitor (•Replace)
engine cooling water exceed •Disconnection in glow plug (•Replace)
20°C, this condition is normal)

Air conditioner operation is defec- •Blown fuse (•Check, repair)

tive •Insufficient battery charge •Charge
•Defective air conditioner switch (•Replace air conditioner switch)
•Defective blower switch (•Replace blower switch)
•Defective compressor (•Replace)

3-112
OPERATION TROUBLESHOOTING

MONITOR PANEL 0.
When an error code appears on the display panel B (multi-
information), take appropriate remedies based upon the table
below.

Abnormal- Method of displaying

Abnormality Remedy
ity code abnormality

•Backup alarm does not sound Displays in turn with ser- Automatic functions stop, some
E01
•Fan rotation is too fast vice meter functions stop, but operation is
possible.
Please contact your Komatsu dis-
tributor for repairs.

E02 •Tilt limit does not work Abnormality code and If user stops engine and then
•Does not shift up or shift down service hour are dis- starts again, operations are pos-
•Pitch does not work played in turn on service sible without limit functions. How-
meter portion, caution ever, user must be careful.
lamp flashes, buzzer Please contact your Komatsu dis-
sounds tributor immediately for repairs.

•Number of speed ranges that Abnormality code and

Move machine to a safe place,
can be used is limited service hour are dis-
then contact your Komatsu dis-
E03+CALL •Engine does not run at full played in turn on service
tributor immediately for repairs.
speed meter portion, caution
•Excessive shock when shifting lamp flashes, buzzer
gear sounds
•Turning ability becomes poor
•Excessive braking shock
•Abnormality in engine water
temperature sensor

•Engine control impossible Abnormality code and Stop machine, then contact your
•Travel impossible service hour are dis- Komatsu distributor immediately
E04+CALL
•Machine does not stop played in turn on service for repairs.
meter portion, caution
lamp flashes, buzzer
sounds

3-113
TROUBLESHOOTING OPERATION

CHASSIS 0.
( ): 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.

Problem Main causes Remedy

•Check, repair
•Improper tightening of oil pipe,
pipe joint, air leaking in or oil leak-
ing out because of damage
(•Check, replace)
•Wear, scuffing of gear pump
Oil pressure in torque converter •Add oil to the specified level. For
•Insufficient oil in power train case
fails to rise details, see CHECK BEFORE
STARTING
•Clean. For details, see EVERY
•Clogged oil filter element strainer
500 HOURS SERVICE
in power train case

•Clogged radiator •Clean radiator core

•Engine water temperature is high •See ENGINE related parts
•Clogged oil cooler (•Clean or replace)
Torque converter is overheats •Oil pressure too low •Go to “Oil pressure in torque con-
verter fails to rise“
•Lack of flow of lubricant caused (•Replace gear pump)
by wear of power train gear pump

•Defective oil temperature gauge (•Replace oil temperature gauge)

Torque converter oil temperature
•defective contact in wiring con- (•Check, repair)
gauge dose not work
nection

•Lack of engine horsepower •See ENGINE related parts

Lacks drawber pull (machine dose
•Oil pressure in torque converter is •Go to “ Oil pressure in torque
not pick up speed)
too low converter fails to rise“

•Insufficient oil inb power train •Add oil to specified level. For
case details, see CHECK BEFORE
STARTING
Machine will not move off when
•Transmission oil pressure does •Go to oil pressure in torque con-
joystick is placed at FORWARD
not rise verter fails to rise
•Defective lever wiring (•Check, repair)
•Parking lever is at LOCK position •Set to FREE position

•Brake is not applied on side which (•Adjust linkage. Check brake

is pulled pressure)
Dose not steer even when steer-
•Parking lever is at LOCK position •Set to FREE position
ing is operated
•Defective lever wiring (•Check, repair)
•Abnormality HSS pump (•Check, replace)
•Abnormality HSS motor (•Check, replace)

Machine doesn't stop when brake •Defective brake adjustment (•Adjust linkage)
pedal are depressed (•Check brake pressure)

•Track is too losse •Adjust track tension. For details,

Track comes off
see WHEN REQUIRED

•Track is too loose or too tight •Adjust track tension. For details,
Sprocket develops abnormal wear
see WHEN REQUIRED

3-114
OPERATION TROUBLESHOOTING

Problem Main causes Remedy

•Defective adjustment of HSS con-

Machine does not travel in straight (•Adjust)
troller
line (•Replace)
•Abnormality HSS pump

•Lack of hydraulic oil •Add oil to specified level. For

details, see EVERY 250 HOURS
blade rises too slowly or dose not
SERVICE
rise at all
•Defective hydraulic pump •Check
(or blade tilts too slowly)
•Work equipment lock lever is at •Set to FREE position
LOCK position

•Lack of hydraulic oil •Add oil to specified level. For

details, see EVERY 250 HOURS
Ripper moves too slowly, does not
•Defective hydraulic pump SERVICE
move
•Work equipment lock lever is at •Check
LOCK position •Set to FREE position

Insufficient force of ripper •Leakage from piping (•Tighten)

3-115
TROUBLESHOOTING OPERATION

ENGINE 0.
( ): 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.

Problem Main causes Remedy

•Engine oil pan oil level is low (sucking •Add oil to specified level, see
in air) CHECK BEFORE STARTING
Engine oil pressure monitor flashes •Clogged oil filter cartridge •Replace cartridge, see EVERY 500
when engine speed is raised after HOURS SERVICE
completion of warm-up •Defective tightening of oil pipe joint, (•Check, repair)
oil leakage from damaged part
•Defective monitor panel (•Replace)

Steam is emitted from top part of radi- •Cooling water level low, water leak- •Add cooling water, repair, see
ator (pressure valve) age CHECK BEFORE STARTING
•Dirt or scale accumulated in cooling •Change cooling water, clean inside
system of cooling system, see WHEN
REQUIRED
•Clogged radiator fin or damaged fin •Clean or repair, see WHEN
Engine water temperature monitor REQUIRED
remains alight altitude operation) •Defective thermostat (•Replace thermostat)
•Loose radiator filler cap (high altitude •Tighten cap or replace packing
operation)
•Defective monitor panel (•Replace)

•Lack of fuel •Add fuel, see CHECK BEFORE

STARTING
•Air in fuel system •Repair place where air is sucked in
Engine does not start when starting
motor is turned •No fuel in fuel filter (•Replace pump or nozzle)
•Starting motor cranks engine slug- •See ELECTRICAL SYSTEM
gishly
•Defective valve compression (•Adjust valve clearance)

•Too much oil in oil pan •Add oil to specified level, see
Exhaust gas is white or blue CHECK BEFORE STARTING
•Improper fuel •Change to specified fuel

•Clogged air cleaner element •Clean or replace, see WHEN

REQUIRED
Exhaust gas occasionally turns black •Defective nozzle (•Replace nozzle)
•Defective compression (•Adjust valve clearance)
•Defective turbocharger (•Clean or replace, turbocharger)

Combustion noise occasionally makes •Defective nozzle (•Replace nozzle)

breathing sound •Lack of fuel (in Air) •Add fuel

•Low grade fuel being used •Change to specified fuel

•Overheating •See item “Indicator of water tempera-
Abnormal noise generated (combus- ture gauge is in red range on right side
tion or mechanical) of gauge“.
•Damage inside muffler (•Replace muffler)
•Excessive valve clearance (•Adjust valve clearance)

Monitor displays error code

Alarm buzzer sounds

Please contact your Komatsu distributor
Engine horsepower lowered suddenly
(Engine is running in duration mode)

3-116
MAINTENANCE
54

WARNING
Please read and make sure that you understand the safety
volume before reading this section.
GUIDES TO MAINTENANCE MAINTENANCE

GUIDES TO MAINTENANCE 0.
Do not carry out any inspection and maintenance operation that is not found in this manual.
Stop the machine on flat hard ground when carrying out inspection and maintenance.

CHECK SERVICE METER 0.

Check the service meter reading every day to see if the time has come for any necessary maintenance to be car-
ried out.

KOMATSU GENUINE REPLACEMENT PARTS: 0.

Use Komatsu genuine parts specified in the Parts Book as replacement parts.

KOMATSU GENUINE OILS: 0.

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem-
perature.

ALWAYS USE CLEAN WASHER FLUID: 0.

Use automobile window washer fluid, and be careful not to let any dirt get into it.

CLEAN OIL AND GREASE: 0.

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

CHECK FOREIGN MATERIAL IN DRAINED OIL: 0.

After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If
large quantity of metal particles or foreign materials are found, always report to the person in charge, and carry out
suitable action.

FUEL STRAINER: 0.
If your machine is equipped with a fuel strainer, do not remove it while fueling.

WELDING INSTRUCTIONS: 0.
Turn off the engine starting switch.
Do not apply more than 200V continuously.
Connect grounding cable within 1m from the area to be welded. If grounding cable is connected near instru-
ments, connectors, etc., the instruments may malfunction.
If a seal or bearing happen to come between the welding part and grounding point, change the grounding point
to avoid such parts.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.

OBJECTS IN YOUR POCKETS: 0.

When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will
lead to failure. If you drop anything inside the machine, always remove it immediately.
Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.

DUSTY WORKSITES: 0.
When working at dusty worksites, do as follows:
Inspect the air cleaner clogging monitor frequently to see if the air cleaner is clogged.
Clean the air cleaner element at a shorter interval than specified.
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.

AVOID MIXING OILS: 0.

If a different type of oil has to be added, drain the old oil and replace all the oil with the new type of oil. Never mix
different kinds of oil.

4-2
MAINTENANCE GUIDES TO MAINTENANCE

LOCKING INSPECTION COVERS: 0.

Lock inspection cover in position securely with the lock bar. If inspection or maintenance is carried out with the
inspection cover not locked in position, there is a hazard that it may be suddenly blown shut by the wind and cause
injury to the worker.

BLEEDING AIR: 0.
When hydraulic equipment has been repaired or replaced, or the hydraulic piping has been removed and installed
again, the air must be bled from the circuit. For details, see “BLEEDING AIR IN HYDRAULIC SYSTEM ( 4-36 )“.

PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES: 0.

When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace with new parts.
When doing this, be careful not to forget to assemble the O-rings and gaskets.
When installing the hoses, do not twist them or bend them into loops with a small radius.
This will cause damage to the hose and markedly reduce its service life.

CHECKS AFTER INSPECTION AND MAINTENANCE: 0.

If you forget carrying out the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious injury or property damage. Always do as follows.
Checks after operation (with engine stopped)
Have any inspection and maintenance points been forgotten?
Have all inspection and maintenance items been carried out correctly?
Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
Is there any leakage of water or oil? Have all the bolts been tightened?
Checks when operating engine
For details of the checks when operating the engine, see “PROPER TOOLS ( 2-25 )“ and pay careful atten-
tion to safety.
Are the inspection and maintenance items working properly?
Is there any leakage of fuel or oil when the engine speed is raised?

4-3
GUIDES TO MAINTENANCE MAINTENANCE

PRECAUTIONS WHEN OPENING AND CLOSING ENGINE SIDE COVER: 0.

When standing on 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.

4-4
MAINTENANCE OUTLINES OF SERVICE

OUTLINES OF SERVICE 0.
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 0.
OIL 0.
Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pres-
sure), and deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Man-
ual.
Even if the oil is not dirty, always change 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 machines 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.
At the time of shipping from the factory, SAE1OWCD is used for hydraulic type of oil. When HO46-hydraulic oil
is going to be used, change specified amount of oil (whole amount). The hydraulic oil that is not recommended
by Komatsu can cause clogging of oil filter, so do not use it. The portion of the oil that remains in the piping or
cylinders will not be a problem even though it will be mixed into new oil.

FUEL 0.
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 -15°C).
It is necessary to use the fuel that is suitable for 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 day's 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.

COOLANT 0.
River water contains large amount 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 antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
Komatsu machines are supplied with Komatsu specified antifreeze in the coolant when the machine is shipped.
This antifreeze is also effective in preventing corrosion of the cooling system.
Replace the antifreeze periodically. For details, see “CLEAN INSIDE OF COOLING SYSTEM ( 4-19 )“.
Antifreeze is flammable, so be extremely careful not to expose it to flame or fire.
The proper mixing proportion of the antifreeze depends on the ambient temperature. For the mixing proportion,
see “CLEAN INSIDE OF COOLING SYSTEM ( 4-19 )“.
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.

4-5
OUTLINES OF SERVICE MAINTENANCE

GREASE 0.
Grease is used to prevent twisting and noise at the joints.
The nipples not included in the MAINTENANCE section are nipples used when overhauling, so they do not
need grease.
If any part becomes stiff or generates noise after being used for a long time, grease it.
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.

CARRYING OUT KOWA (Komatsu Oil Wear Analysis) 0.

KOWA is a maintenance service that makes it possible to prevent machine failures and down-time. With KOWA,
the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and
other abnormalities.
Periodic use of KOWA makes the following possible:
It enables abnormalities to be detected early, leading to reduction of repair costs and machine downtime.
It enables repair schedules to be planned, leading to improved machine availability.

KOWA ANALYSIS ITAMS 0.

Analysis of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of metal wear particles in the oil.

Measurement of particle quantity

This uses a PQI (Particle Quantifier Index) measurer to
measure the quantity of large iron particles in the oil.

Others
Measurements are made of items such as the ratio of water or fuel in the oil, and the dynamic viscosity.

OIL SAMPLING 0.
Sampling interval
250 hours: Engine
500 hours: Other components
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Carry out sampling regularly at fixed intervals.
Do not carry out sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.

4-6
MAINTENANCE OUTLINES OF SERVICE

STORING OIL AND FUEL 0.

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).

FILTERS 0.
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
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 affixed 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.

OUTLINE OF ELECTRIC SYSTEM 0.

It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged.
This will cause electrical leakage and may lead to malfunction of the machine.
Inspection and maintenance works include checking the fan belt for tension and damage as well as the battery
for electrolyte level.
Never remove or disassemble any electric components installed in the machine.
Never install any electric components other than those specified by Komatsu.
Be careful to keep the electric system free of water when washing the machine or when it rains.
When working on the seashore, carefully clean the electric system to prevent corrosion.
Never connect any opetional power source to the fuse, starting switch, battery relay, etc.

4-7
WEAR PARTS LIST MAINTENANCE

WEAR PARTS LIST 0.

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.
When requesting parts, check their part numbers from the parts list.

WEAR PARTS LIST 0.

The parts in parentheses are to be replaced at the same time.

Weight Replacement
Item Part No. Part Name Q'ty
(kg) frequency

Engine oil filter 600-211-1340 Cartridge - 1

07063-01100 Element - 1 Every 500

Transmission filter
(07000-02130) (O-ring) - (1) hours service

Fuel filter 600-311-3110 Cartridge - 1

Corrosion resistor 600-411-1151 Cartridge - 1

Every 1000
Hydraulic tank hours service
20Y-60-21470 Element - 1
breather element

207-60-71180 Element - 1 Every 2000

Hydraulic oil filter
(07000-05195) (O-ring) - (1) hours service

6125-81-7032 Element Ass'y - 1 -

Air cleaner Outer element
600-181-4300 - 1 -
assembly

154-70-11314 Cutting edge 52.9 1

154-71-43190 Cutting edge - 2
(154-71-41270) (Bolt) - (20)
(01643-21845) (Washer) - (20)
(154-70-22270) (Nut) - (20)
D85EX -
150-70-21346 End bit (right) - 1
150-70-21356 End bit (left) - 1
Blade (154-71-41270) (Bolt) - (12)
(01643-21845) (Washer) - (12)
(154-70-22270) (Nut) - (12)

154-70-11314 Cutting edge 52.9 3

(154-71-41270) (Bolt) - (24)
D85PX -
(01643-21845) (Washer) - (24)
(154-70-22270) (Nut) - (24)

154-78-31330 Protector - 3
Ripper
175-78-31230 Point - 3 -
(variable multi ripper)
(09244-02508) (Pin) - (9)

NOTICE
When handling parts that weigh more than 25 kg, remember that they are heavy objects, and take the nec-
essary care.

4-8
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING

TO AMBIENT TEMPERATURE 0.
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 0.

AMBIENT
CAPACITY
Kind of TEMPERATURE
Reservoir Type
fluid
Min Max Specified Refill

0°C 40°C SAE 30

-20°C 10°C SAE 10W
Engine oil pan 44 liter 38 liter
-15°C 40°C SAE 15W-40
-20°C 40°C SAE 10W-30

Power train oil pan

(incl. transmission,
0°C 40°C SAE 30 90 liter 60 liter
torque converter and
bevel gear casses) -20°C 10°C SAE 10W
Engine oil
Final drive case (each) 26 liter 26 liter

Damper case -20°C 40°C SAE 30 1,5 liter 1,5 liter

-20°C 40°C SAE 10W (EX)120

liter
Hydraulic system -20°C 40°C SAE 10W-30 67 liter
(PX) 106
-15°C 40°C SAE 15W-40 liter

-10°C 40°C ASTM D975 No. 2

Fuel tank Diesel fuel -20°C -10°C ASTM D975 No. 1 490 liter
(for winter use)

Cooling sytem Water Add antifreeze 82 liter

Grease fitting Grease -20°C 40°C NLGI No. 2

4-9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE

REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic mainte-
nance hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.

When starting the engine with an atmospheric temperature of lower than 0°C, be sure to use engine oil
of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C
more or less during the day.

Use API classification CD as engine oil and if API classification CC, reduce the engine oil change inter-
val to half.

There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to
add single grade oil that matches the temperature range in the table.

We recommend Komatsu genuine oil which has been specifically formulated and approved for use in
engine and hydraulic work equipment applications.

Specified capacity: Total amount of oil including oil for components and oil in piping.

Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute

Change interval of oil in

Fuel sulphur content
engine oil pan

0.5 to 1.0% 1/2 of regular interval

Above 1.0% 1/4 of regular interval

4-10
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

Engine Oil
Antifreeze
[CD or CE]
Gear Oil Grease Coolant
No SAE10W, 30, 40
Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
. 10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)

AF-ACL
EO10-CD
AF-PTL
KOMATS EO30-CD GO90 G2-LI
1 AF-PT(Winter,
U EO10-30CD GO140 G2-LI-S
one
EO15-40CD
season type)

Diesel sigma S
super dieselmulti-
2 AGIP Rotra MP GR MU/EP -
grade
*Sigma turbo

Multi-purpose gear PYKON premium

3 AMOCO *Amoco 300 -
oil grease

Litholine HEP 2
4 ARCO *Arcofleet S3 pius Arco HD gear oil -
Arco EP moly D

Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP

Universal thuban
*RPM delo 400 Marfak all purpose 2 AF engine cool-
6 CALTEX Universal thuban
RPM delo 450 Ultra-duty grease 2 ant
EP

EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Antifreeze
Spheerol EPL2
CRD Hypoy B
Hypoy C

CHEV-
8 *Delo 400 Universal gear Ultra-duty grease 2 -
RON

Universal gear
9 CONOCO *Fleet motor oil Super-sta grease -
lubricant

Multiperformance 3C Tranself EP
10 ELF - Glacelf
Performance 3C Tranself EP type 2

Essolube D3
*Essolube XD-3
EXXON Gear oil GP All season cool-
11 *Essolube XD-3 Extra Beacon EP2
(ESSO) Gear oil GX ant
*Esso heavy duty
Exxon heavy duty

Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant

Delvac 1300 Mobilux EP2

Mobilube GX
13 MOBIL *Delvac super Mobilgease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special

4-11
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE

Engine Oil
Antifreeze
[CD or CE]
Gear Oil Grease Coolant
No SAE10W, 30, 40
Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
. 10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)

Multi-purpose white
PEN- *Supreme duty Multi-purpose 4092 grease 705 Antifreeze and
14
NZOIL fleet motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease

PETRO- FINA potonic N

15 FINA kappa TD FINA marson EPL2 FINA tamidor
FINE FINA potonic NE

Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty

Sunoco anti-
Sunoco ultra prestige
Sunoco GL5 freeze
17 SUN - 2EP
gear oil and summer
Sun prestige 742
coolant

Coda 2055 star-

*Ursa super plus Multifak EP2 tex
18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze cool-
ant

Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
TM

20 UNION *Guardol MP gear lube LS Unoba EP -

*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C

4-12
MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

STANDARD TIGHTENING TORQUES FOR BOLTS AND

NUTS 0.
TORQUE LIST 0.
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to
the tightened parts, and this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that
was replaced.

Tightening torque
Thread
Width
diameter of
across flats Target value Service limit
bolt
(b)(mm)
(a)(mm)
N·m kgf·m N·m kgf·m

6 10 13.2 1.35 11.8-14.7 1.2-1.5

8 13 31 3.2 27-34 2.8-3.5
10 17 66 6.7 59-74 6.0-7.5
12 19 113 11.5 98-123 10.0-12.5
14 22 177 18 157-196 16.0-20.0

16 24 279 28.5 245-309 25.0-31.5

18 27 382 39 343-425 35.0-43.5
20 30 549 56 490-608 50.0-62.0
22 32 745 76 662-829 67.5-84.5
24 36 927 94.5 824-1030 84.0-105.0

27 41 1320 135.0 1180-1470 120.0-150.0

30 46 1720 175.0 1520-1910 155.0-195.0
33 50 2210 225.0 1960-2450 200.0-250.0
36 55 2750 280.0 2450-3040 250.0-310.0
39 60 3280 335.0 2890-3630 295.0-370.0

Apply the following table for Hydraulic Hose.

Nominal- Width across Tightening torque (N·m (kgf·m))

No. of flats (b)
threads (a) mm Target valve Parmissible range

9/16 -18UNF 19 44 (4.5) 35 - 63 (3.5 - 6.5)

11/16 -16UN 22 74 (7.5) 54 - 93 (5.5 - 9.5)

13/16 -16UN 27 103 (10.5) 84 - 132 (8.5 - 13.5)

1 -14UNS 32 157 (16.0) 128 - 186 (13.0 - 19.0)

13/16 -12UN 36 216 (22.0) 177 - 245 (18.0 - 25.0)

4-13
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS0.

For using the machine safely for an extended period of time, you are requested to periodically replace the safety -
critical and fire prevention- related parts listed in the table of important parts on the following page.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is
required to replace them with new ones regardless of their condition after a certain period of usage. This is impor-
tant to ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the peri-
odic replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also carry out the following checks with hydraulic hoses which need not be replaced periodically. Tighten a loos-
ened clamp or replace a defective hose, as required.
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.
Check the hydraulic hoses and the fuel hose, too, when carrying out the following periodic inspections.

Interval Check items

Check before starting Oil leakage from the connections or the clamps of fuel and hydraulic hose

Oil leakage from the connections or the clamps of fuel and hydraulic hose.
Monthly inspection
Damage (crack, wear and tear) of fuel and hydraulic hose.

Oil leakage from the connections or the clamps of fuel and hydraulic hose.
Yearly inspection Interference, deformation, deterioration and damage (crack, wear and tear) of fuel
and hydraulic hose.

4-14
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

SAFETY CRITICAL PARTS 0.

Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before
they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of
the machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check the latest part number when ordering parts.

No. Safety critical parts for periodic replacement Q'ty Replacement interval

1 Fuel hose (nozzle - fuel return hose) 1

2 Fuel hose (scavenging pump - fuel return hose) 1

3 Fuel hose (fuel tank - fuel strainer) 1

4 Fuel hose (fuel strainer - scavenging pump) 1

5 Fuel hose (hand priming pump - supply pump) 1

6 Hose (Torque converter oil cooler - power train assembly) 1

7 Hose (power train pump - power train filter) 1

8 Hose (Transmission filter - power train assembly) 1

9 Hose (transmission case - steering case) 1

10 Inspection hose assembly for power train pressure 1

11 Hose (right pivot shaft cover - straight frame relay tube) 2

12 Hose (straight frame relay tube - blade tilt CYL) 2

13 Hose (HSS motor - main control valve) 2

14 Hose (HSS pump - central drain block) 1 Every 2 years or 4000 hours,
15 Hose (HSS motor - central drain block) 1 whichever comes sooner

16 Hose (central drain block (P/L) - main control valve) 1

17 Hose (oil cooler - central drain block) 2

18 Hose (Fan pump - self-reducing pressure valve) 1

19 Hose (self-reducing pressure valve - fan motor) 3

20 Hose (PCC divider block - main control valve) 2

21 Hose (PCC divider block - fan pump) 1

22 Hose (PCC divider block - main control lock valve) 2

23 Hose (oil cooler bypass valve - hydraulic oil cooler) 2

24 Hose (self-reducing pressure valve - central drain block) 1

25 Hose (main control valve - central drain block) 1

26 Hose (fan motor - hydraulic tank) 4

27 Hose (self-reducing pressure valve - PPC lock valve) 1

28 Hose (PPC lock valve - blade PPC lock valve) 1

4-15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE

No. Safety critical parts for periodic replacement Q'ty Replacement interval

29 Hose (PPC lock valve - ripper PPC valve) 1

30 Hose (blade PPC valve - main control valve) 4

31 Hose (ripper PPC valve - main control valve) 2

32 Hose (blade PPC valve - central drain block) 1

33 Hose (ripper PPC valve - central drain block) 1

34 Hose (HSS pump - main control valve) 2

35 Hose (main control valve - ripper relay block) 2 Every 2 years or 4000 hours,
36 Hose (oil cooler bypass valve - hydraulic tank) 1 whichever comes sooner

37 Hose (ripper relay block - ripper cylinder) 4

38 Hose (main control valve - blade tilt relay cover) 4

39 Hose (main control valve - blade relay tube) 2

40 Hose (central drain block - hydraulic tank) 1

41 Hose (radiator guard top - lift cylinder) 24

42 Injector nozzle tip 1S

43 Seat belt 1 Every 3 years

44 High-pressure tube clamp 1S

Every 8000 hours
45 Fuel spray prevention cap 1S

4-16
MAINTENANCE MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART 0.

MAINTENANCE SCHEDULE CHART 0.
INTIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS) 0.
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN
HYDRAULIC TANK STRAINER.......................................................................................................................... 4-53
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................................... 4-54

WHEN REQUIRED 0.
CLEAN INSIDE OF COOLING SYSTEM........................................................................................................... 4-19
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ............................................................................ 4-21
CHECK TRACK TENSION ................................................................................................................................. 4-24
CHECK AND TIGHTEN TRACK SHOE BOLTS ................................................................................................. 4-25
ADJUST IDLER CLEARANCE............................................................................................................................ 4-26
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES................................................................ 4-28
CLEAN, CHECK RADIATOR FINS..................................................................................................................... 4-29
CLEAN FUEL TANK STRAINER ........................................................................................................................ 4-29
DRAIN WATER AND SEDIMENT IN FUEL TANK ............................................................................................. 4-30
CLEAN STEERING CLUTCH CASE BREATHER.............................................................................................. 4-30
REPLACE AIE CONDITIONER BELT ................................................................................................................ 4-30
CLEAN, CHECK HYDRAULIC COOLER FINS .................................................................................................. 4-30
CHECK UNDERCARRIAGE OIL ........................................................................................................................ 4-31
CLEAN AIR CONDITIONER AIR FILTER(FRESH/RECIRC FILTER)................................................................ 4-32
CHECK, ADJUST AIR CONDITIONER .............................................................................................................. 4-32
LUBRICATE DOOR HINGE................................................................................................................................ 4-33
CHECK DOOR LATCH ....................................................................................................................................... 4-34
CHECK DOOR LOCK STRIKER ........................................................................................................................ 4-34
REPLACE DOOR DAMPER ............................................................................................................................... 4-34
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ................................................................................. 4-35
REPLACE WIPER BLADE.................................................................................................................................. 4-35
BLEEDING AIR IN HYDRAULIC SYSTEM......................................................................................................... 4-36
CHECK ELECTRICAL INTAKE AIR HEATER.................................................................................................... 4-36
LUBRICATING .................................................................................................................................................... 4-36

CHECK BEFORE STARTING 0.

EVERY 250 HOURS SERVICE 0.

LUBRICATING .................................................................................................................................................... 4-38
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST ............................................................................... 4-40
CHECK LEVEL OF BATTERY ELECTROLYTE................................................................................................. 4-41
CHECK BRAKE PERFORMANCE ..................................................................................................................... 4-43
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ............................................................................................ 4-44

EVERY 500 HOURS SERVICE 0.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS
FILTER CARTRIDGE.......................................................................................................................................... 4-45
REPLACE FUEL FILTER CARTRIDGE.............................................................................................................. 4-46
REPLACE POWER TRAIN OIL FILTER ELEMENT, STEERING LUBRICATING OIL FILTER ELEMENT ....... 4-47
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...................................................................................... 4-48
REPLACE HYDRAURIC TANK BREATHER ELEMENT.................................................................................... 4-48

4-17
MAINTENANCE SCHEDULE CHART MAINTENANCE

EVERY 1000 HOURS SERVICE 0.

CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS(POWER TRAIN PUMP STRAINER,
SCAVENGING PUMP STRAINER) .................................................................................................................... 4-49
CHECK, CLEAN FUEL STRAINER .................................................................................................................... 4-51
REPLACE CORROSION RESISTOR CARTRIDGE........................................................................................... 4-52
CHECK TIGHTENING PARTS OF TURBOCHARGER ...................................................................................... 4-52

EVERY 2000 HOURS SERVICE 0.

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC
TANK STRAINER ............................................................................................................................................... 4-53
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................................... 4-54
CHANGE OIL IN DAMPER CASE, CLEAN DANPER BREATHER.................................................................... 4-55
CHECK PIVOT BEARING OIL LEVEL, ADD OIL ............................................................................................... 4-56
CLEAN ENGINE BREATHER ELEMENT ........................................................................................................... 4-56
CHECK ALTERNATOR, STARTING MOTOR .................................................................................................... 4-56
CHECK INJECTOR............................................................................................................................................. 4-56
CHECK VIBRATION DAMPER ........................................................................................................................... 4-56
CLEAN, CHECK TURBOCHARGER .................................................................................................................. 4-56
CHECK PLAY OF TURBOCHARGER ROTOR .................................................................................................. 4-56
CHECK ENGINE VALVE CLEARANCE, ADJUST ............................................................................................. 4-57

EVERY 4000 HOURS SERVICE 0.

CHECK WATER PUMP ...................................................................................................................................... 4-58
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......................... 4-58
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER........................... 4-59
REPLACE INJECTOR ASSEMBLY .................................................................................................................... 4-59
CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER) ...................................................................... 4-60

EVERY 8000 HOURS SERVICE 0.

REPLACE HIGH-PRESSURE PIPING CLAMP .................................................................................................. 4-61
REPLACE FUEL SPRAY PREVENTION CAP ................................................................................................... 4-61

4-18
MAINTENANCE SERVICE PROCEDURE

SERVICE PROCEDURE 0.
INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS) 0.
Carry out the following maintenance only after the first 250 hours.
Change oil in hydraulic tank, replace hydraulic oil filter element, clean hydraulic tank strainer
Change oil in final drive case
For details of the method of replacing or maintaining, see the section on EVERY 2000 HOURS SERVICE.

WHEN REQUIRED 0.
CLEAN INSIDE OF COOLING SYSTEM 0.

WARNING
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under
high internal pressure. If the cap is removed to drain the coolant in this condition, there is a hazard of
burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before
removing it.
Cleaning is carried out with the engine running. When standing up or leaving the operator's seat, set
the safety lock lever and the parking lever to the LOCK position.
For details of starting the engine, see “CHECK BEFORE STARTING ENGINE, ADJUST ( 3-55 )“ and
“STARTING ENGINE ( 3-71 )“ in the OPERATION section.
Never enter front the machine when the engine is running.
There is danger of touching the fan.

Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the
table below.

Cleaning inside of cooling system

Kind of coolant Replacing corrosionÅresistor
and changing coolant

Every year (autumn) or

Permanent type antifreeze
every 2000 hours,
(All season type)
whichever comes first
Every 1000 hours and when
Non permanent type antifreeze Every 6 months (spring, autume)
cleaning the inside of the
containing ethylene glycol (Drain antifreeze in spring,
cooling system and
(winter, one season type) add antifreeze in autumn)
when changing coolant
Every 6 months or
When no using antifreeze every 1000 hours,
whichever come first

Stop the machine on level ground when cleaning or changing the coolant.
Use a permanent type of antifreeze.
If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol.
Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect.
The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect,
a minimum ratio of 30% by volume is necessary.
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mix-
ing rate table given below.
It is actually better to estimate a temperature about 10°C lower when deciding the mixing rate.

4-19
SERVICE PROCEDURE MAINTENANCE

Mixing rate of water and antifreeze

Min. atmospheric
°C - 10 - 15 - 20 - 25 - 30
temperature

Amount of anti-
liters 39.0 46.7 53.2 59.7 65.0
freeze

Amount of water liters 91.0 83.3 76.8 70.3 65.0

WARNING
Antifreeze is flammable, so keep it away from flame.
Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on
you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.

Use city water for the cooling water.

If river water, well water or other such water supply must be used, contact your Komatsu distributor.
We recommend use of an antifreeze density gauge to control the mixing proportions.

WARNING
When removing the drain plug, be careful not to be covered with the drained coolant.
1. Stop the engine, wait for the coolant to cool completely, then
turn valve (2) of corrosion resistor (1) to the Close stopper
position.

2. Turn main radiator cap (3) slowly, and remove.

4-20
MAINTENANCE SERVICE PROCEDURE

3. Prepare a container to catch the coolant, pull out hose (4) of

the main radiator at the bottom front right of the machine,
then open drain valve (5) and drain the water.
4. Open the drain valve (6) in the water pump piping on the
right side of the engine, and drain the water.
5. After draining, close up drain valve (5), (6) and pour in clean
water up to the vicinity of the water filler.
6. When the radiator is full of water, open drain valves (5), (6),
then start the engine and run at low idling. Continue to run
the engine at low idling and flush the radiator for 10 min-
utes.
While flushing with water, adjust the input flow and drain
flow of water so that the radiator remains full during the
flushing operation. During the flushing operation, take care
that the filler hose does not come out from the radiator cap
water from the port.
7. After washing the cooling system, stop the engine. Drain
water and close drain valve (5), (6).
8. After draining the water, flush the system with a flushing
agent.
9. After flushing, open drain valve (5), (6), completely drain all
the water, then close the drain valve and drain plug, and fill
with city water up to near the filler port.
10.When the tank is filled to near the water filler port, open
drain valve (5), (6), start the engine, run at low idling, and
continue the flushing operation until clean water comes out.
11. When clean water comes out, stop the engine and close drain valve (5), (6).
12.Replace the corrosion resistor, then open each valve (3).
For details of the procedure for replacing the corrosion resistor, see “REPLACE CORROSION RESISTOR
CARTRIDGE ( 4-52 )“.
13.Add city water until the water overflows from the water filler port.
14.To remove the air in the cooling system, run the engine for 5 minutes at low idling, and for another 5 minutes at
high adling. (When doing this, leave the radiator cap off.)
15.Open cap (7) at the top of the coolant reserve tank, then
add water to the specified level. For details, see “CHECK
COOLANT LEVEL, ADD WATER ( 3-57 )“.
16.Stop the engine, wait for 3 minutes, add city water until the
water level reaches near the water filler port, then tighten
the cap (3).

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 0.

WARNING
Always wear protective glasses,dust mask,or other protective equipment.
When removing the air cleaner element from the air cleaner body,it is dangerous to pull it out by force.
When working at high places or where the foothold is poor, be careful not to fall because of the reac-
tion when pulling out the outer element.

4-21
SERVICE PROCEDURE MAINTENANCE

CHECKING 0.
If the internal yellow piston overlaps the red zone on the out-
side diameter of dust indicator (1), clean the air cleaner ele- Red zone
ment.
After cleaning, press the reset button to reset the piston.

NOTICE
Always wait for the yellow piston in the dust indicator to
overlap the red zone on the outside before cleaning the
element.
If the element is cleaned frequently before the yellow pis-
ton in the dust indicator overlaps the red zone on the out-
side, the air cleaner will be unable to display its normal
performance and the cleaning effect will become poor.
In addition, the frequency of dust stuck to the element fall-
ing inside the inner element during the cleaning operation
will increase.

CLEANING OR REPLACING OUTER ELEMENT 0.

NOTICE
Before and after cleaning the element, do not leave or keep
it in direct sunlight.

1. Remove 3 hooks (2) , then remove cover (3).

Remove outer element.
2. Hold the outer element, rock it lightly up and down and to
the left and right, and rotate the element to the left and right
to pull it out.

NOTICE
Never remove the inner element. It will allow dirt to
Inner element
enter and cause failure of the engine.
Do not use a screwdriver or other tool.
3. After removing the outer element, cover the air connector
inside the air cleaner body with a clean cloth or tape to pre- Outer element
vent dirt or dust from entering.

4. Use a clean cloth or brush to remove the dirt stuck to the

cover and the inside of the air cleaner body.
5. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2, 99.4
PSI)) from the inside of the outer element along its folds.
Then direct the compressed air from the outside along the
folds, and again from the inside.
1) Check that the inner element is not loose. If it is loose,
insert it securely.
2) If the yellow piston overlaps the outer element red zone
immediately after the outer element is cleaned, replace
the inner and outer elements.
6. Remove the cloth or tape cover installed in Step 3.
7. 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.

4-22
MAINTENANCE SERVICE PROCEDURE

NOTICE
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.

8. After replacing the element, press the dust indicator button

to reset it.
The yellow piston will return to its original position.

REPLACING INNER ELEMENT 0.

1. First remove the outer element, and then remove the inner
element.
2. Cover the air connector side (outlet side) with a clean cloth
or tape.
3. Clean the air cleaner body interior, then remove the cover
installed in Step 2.
4. Fit a new inner element to the connector.
Do not clean and reinstall a inner element.
5. Install the outer element and the cover.

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SERVICE PROCEDURE MAINTENANCE

CHECK TRACK TENSION 0.

The wear of pins and bushings on the undercarriage will vary with the working conditions and types of soil. It is
thus necessary to continually inspect the track tension so as to maintain the standard tension.
Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track
becomes clogged with mud, measure with the track clogged with mud).

INSPECTION 0.
Stop the machine on level ground (stop with the transmission in
FORWARD without applying the brake). Then place a straight
bar on the track shoes between the carrier roller and the idler
as shown in the figure, and measure the clearance between
the bar and the grouser at the midpoint. If the clearance (A) is
20 to 30 mm, the tension is standard.
If the track tension is not at the standard value, adjust it in the
following manner.

ADJUSTMENT 0.

WARNING
Grease inside adjusting mechanism is under high pres-
sure. Grease coming from lubricator (1) under pressure
can penetrate the body causing injury or death.
For this reason, do not loosen lubricator (1) more than
one turn. Do not loosen any part other than lubricator (1).
Furthermore, do not get any part of your body in front of
the grease fitting.
If the track tension is not relieved by this procedure,
please contact your Komatsu distributor.

WHEN INCREASING TENSION 0.

1. Pump in grease through grease fitting (2) with a grease
pump.

2. To check that the correct tension has been achieved, move

the machine backwards and forwards.

3. Check the track tension again, and if the tension is not cor-
rect, adjust it again.

4. Continue to pump in grease until (S) becomes 0 mm. 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.

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MAINTENANCE SERVICE PROCEDURE

WHEN LOOSENING TENSION 0.

WARNING
It is extremely dangerous to release the grease by any method except the procedure given below. If the
track tension is not relieved by this procedure, please contact your Komatsu distributor.

1. Loosen lubricator (1) gradually to release the grease.

2. Turn lubricator (1) a maximum of one turn.

3. If the grease does not come out smoothly, move the

machine forwards and backwards a short distance.

4. Tighten lubricator (1).

5. To check that the correct tension has been achieved, move

the machine backwards and forwards.

6. Check the track tension again, and if the tension is not cor-
rect, adjust it again.

WHEN REMOVING TRACK 0.

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 ( 4-25 )“ does not
loosen the track tension, please contact your Komatsu distributor for repair.

CHECK AND TIGHTEN TRACK SHOE BOLTS 0.

If the machine is used with track shoe bolts being loose, they will break, so tighten any loose bolts immediately.

METHOD OF TIGHTENING SHOE BOLT 0.

1. First, tighten to the tightening torque below, then check that the nut and shoe are in close contact with the link
mating surface.
D85EX: 343 ± 39 N·m (35 ± 4 kgf·m)
D85PX: 539 ± 49 N·m (55 ± 5 kgf·m)
2. After checking, tighten a further 120° ± 10°.

METHOD OF TIGHTENING MASTER LINK CONNECTING BOLT 0.

1. First tighten to a tightening torque of 343 ± 39 N·m (35 ± 4 kgf·m) then check that the link contact surfaces are
in close contact.
2. After checking, tighten a further 160° to 180°.

ORDER FOR TIGHTENING 0.

Tighten the bolts in the order shown in the diagram on the right.

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SERVICE PROCEDURE MAINTENANCE

ADJUST IDLER CLEARANCE 0.

The idler moves forward and backward under external pres-
sure when this happens, side guide 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.

ADJUSTING IN SIDEWAYS DIRECTION 0.

1. Drive the machine for 8 to 12 m on flat ground, then mea-
sure clearance A (4 places: left, right, inside outside)
between the track frame and side guide (1).
2. If clearance A is more than 4 mm, remove bolt (1), then take
out shim, and adjust to that the clearance on one side is
less than 0.5 to 1 mm.
REMARK
There are two types of shim (thickness: 0.5 mm and 1.0
mm).

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MAINTENANCE SERVICE PROCEDURE

ADJUSTING IN VERTICAL DIRECTION 0.

1. To determine the amount of adjustment, measure clearance
B, then subtract 2 mm and record the result (amount of
adjustment).

Example
If clearance B = 5 mm:
Amount of adjustment = 5 - 2 = 3 mm

2. Loosen bolts (9) (inside, outside: Total 4) to a point where

there is no more reaction from the spring.
3. Loosen bolt (1) (inside, outside: Total 8) . When doing this,
do not loosen it more than 3 turns.
4. Using a bar, pull up up-down guide (5) to set clearance C to
0, then remove shims of a thickness equal to the amount of
adjustment measured in Step 1.
5. After removing shims (7), add them on top of shim (8).
(Left, right, inside, outside: Total 8 places)
When doing this, check that the total thickness of shim (7)
and shim (8) is the same after adjustment as it was before
adjustment at all places.
Discarding shims or adding shims will result in improper
function of the built-in spring.

REMARK
There are two types of shim thickness: 1 mm and 2 mm.

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SERVICE PROCEDURE MAINTENANCE

REVERSE AND REPLACE THE END BITS AND CUTTING EDGES 0.

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 lock lever to the LOCK position.
If the cutting edge and the end bit on both sides are worn out, replace with new one.
If it has been worn out up to the fitting surface, repair the fitting surface and then reverse or replace.
3. Loosen nut (1) and remove bolt (2). Then remove the cut-
ting 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 (1) and nut (2) are damaged, replace them with new
ones 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 (2), then tighten it to the correct tightening
torque. When installing end bit (3), put top surface (4) of the
end bit in close contact with stopper (5), then tighten with
the bolts.
Tightening torque: 628 ± 79 N·m (64 ± 8 kgf·m)
6. After several hours of running, retighten the nuts.

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MAINTENANCE SERVICE PROCEDURE

CLEAN, CHECK RADIATOR FINS 0.

WARNING
For the cleaning and check, stop the engine without fail and confirm that the fan is not rotating, and carry
out the work.
Be sure to close the radiator grille before turning the radiator fan so that no one will touch the turning fan
carelessly.

When the radiator fin block with mud, dirt or leaves, clean it as follows.
1. Remove bolts (1) at the four corners of the radiator fins,
then open radiator grill (2).

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.

When cleaning the radiator fins, reverse the rotation of the fan
and change the direction of the air flow. Set the Fan rotation
selector switch to the CLN position (C) and start the engine.
The fan rotates at 100% speed in reverse and cleans the fins.
The Fan rotation selector switch cannot be operated when the
engine is running.

REMARK
If dirt is caught in the radiator fins, blow with compressed air to clean.

CLEAN FUEL TANK STRAINER 0.

Clean the strainer if there is any dirt collected in it.
Remove the filler cap (1) of the fuel tank and take out strainer.
If the strainer is dirty, clean it with diesel fuel.

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SERVICE PROCEDURE MAINTENANCE

DRAIN WATER AND SEDIMENT IN FUEL TANK 0.

Carry out this procedure after the mchine has been at rest for a
long time and after a long spell of rainy days.
Loosen valve (1) at the bottom of the tank and drain sediment
accumulated on the bottom together with mixed water and fuel.

CLEAN STEERING CLUTCH CASE BREATHER 0.

1. Open the valve cover.
2. Remove the bolts, then remove cover (1).
3. Remove breather (2) at the side of the hydraulic tank,
remove the dirt stuck to the breather, then wash it in clean
diesel oil or flushing oil.

REPLACE AIR CONDITIONER BELT 0.

1. Loosen 4 bolts (1) and jack bolt (2), then move compressor
(3) to the side.
2. Replace the V-belt.
When adjusting the V-belt, do not push the compressor
directly with the bar. Use jack bolt (2).
3. Tighten jack bolt (2) and bolts (1), and apply tension to the
V-belt. The standard deflection for the belt is approx. 10
mm when pressed with a finger force of approx. 6 kg at a
point midway between the air conditioner compressor pulley
and fan pulley.

CLEAN, CHECK HYDRAULIC COOLER FINS 0.

If the hydraulic cooler fins are clogged or there is dirt caught in
the fins, clean and check the fins.
1. Open the radiator mask.
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
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.

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MAINTENANCE SERVICE PROCEDURE

CHECK UNDERCARRIAGE OIL 0.

Stop the machine on level ground, and check for any reduction
in the oil at the idler (portion P), track roller (portion Q), and car-
rier roller (portion R).

1. Loosen seal bolt (1) 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 (1) is removed, the
oil level is low, so please contact your Komatsu distributor
for repair.

4-31
SERVICE PROCEDURE MAINTENANCE

CLEAN AIR CONDITIONER AIR FILTER(FRESH/RECIRC FILTER) 0.

Clean the air conditioner air filter if it becomes clogged or if
there is dirt or oil stuck to it.
1. Open inspection cover (1) on top of the hood, then remove
pressure air filter (2).
2. Open inspection cover (3) under the front panel and pull up
recirculation air filter (4) to remove it.
3. Clean filters (2) and (4) 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 filters cannot be cleaned with air or in water, replace
them with new ones.

CHECK, ADJUST AIR CONDITIONER 0.

CHECK TENSION OF COMPRESSOR BELT 0.

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 Compressor pulley
drive pulley and compressor pulley with your finger (approx. 6
kg) and check that the tension is 15 to 18 mm.
When the belt is new, there will be initial elongation, so always
adjust again after 2 or 3 days.

Drive pulley

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MAINTENANCE SERVICE PROCEDURE

CHECK LEVEL OF REFRIGERANT (GAS) 0.

WARNING
When handling refrigerant gas, always follow local
laws and regulations.
The refrigerant used in the cooler is colorless and
odorless and does not harm the atmosphere, but if the
liquid gets into your 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 Sight glass
be reduced. Run the engine at high idling, and check the flow
A
of the refrigerant in the refrigerant circuit through the sight
glass of the receiver (1) when the cooler is running at high
speed. B
No bubbles in refrigerant flow: Suitable (A)
Some bubbles in flow (bubbles pass continuously): Lack of C
refrigerant (B)
Colorless, transparent: No refrigerant (C)
Receiver
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 R134a is used as the refrigerant.

LUBRICATE DOOR HINGE 0.

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.

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SERVICE PROCEDURE MAINTENANCE

CHECK DOOR LATCH 0.

WARNING
If the control lever is touched by accident during check-
ing, the machine moves off suddenly, and this may lead to
serious injury or death.
Before checking door latch, stop the engine and set the
parking lever securely to the LOCK position.
Free
Lock
Check
Hold the door open-locked, and check that there is still grease
inside the latch. If the amount of grease is low or there is no
more grease, coat the inside of the latch with grease from por-
tion (1).

REMARK
If there is no more grease inside the latch, the movement
will become poor because of dust inside the latch, and the
handle may be stiff when opening the door.

CHECK DOOR LOCK STRIKER 0.

If the wear of the door lock striker exceeds 0.5 mm, 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.

View Z

REPLACE DOOR DAMPER 0.

If the depth of the door damper rubber groove is less than 2
mm, replace the damper.
There are two dampers each at the top and bottom on the left Less than 2 mm
and right doors.

Rubber

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MAINTENANCE SERVICE PROCEDURE

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID 0.

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 (1), and if it is low, add automobile window washer
fluid.
When adding fluid, be careful not to let any dust get in.

REPLACE WIPER BLADE 0.

If the blade is damaged, it will not wipe the window clean, so
replace the blade.

REPLACEMENT 0.

FRONT, REAR WIPER 0.

1. It is hooked at portion (A), so move the blade in the direction
of the arrow to remove it.
2. Install the new blade and hook it securely.

REAR WIPER 0.
1. Remove E-ring(1).
The blade can then be removed.
2. Install a new blade, then install securely with E-ring (1).

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SERVICE PROCEDURE MAINTENANCE

DOOR WIPER 0.
1. It is hooked at portion (A), so move the blade in the direction
of the arrow to remove it.
2. Install the new blade and hook it securely.

BLEEDING AIR IN HYDRAULIC SYSTEM 0.

See “OPERATIONS AND CHECKS AFTER STARTING ENGINE ( 3-75 )“.
Since the engine must be started and the blade must be operated, see OPERATION.

NOTICE
If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air
taken inside the cylinder may cause damage to the piston packing.

1. Bleeding air from cylinders

1) Run the engine at low idling, and extend and retract each cylinder 4 to 5 times, taking care so that a cylinder
may not be brought up to its stroke end. (Stop the cylinder approx. 100 mm short of its stroke end)
2) Next, operate each cylinder 3 to 4 times to the end of its stroke.
3) Finally, operate each cylinder 4 to 5 times to the end of its stroke to completely remove the air.

CHECK ELECTRICAL INTAKE AIR HEATER 0.

Check before the cold season starts (once a year).
Remove the electric heater from the engine intake manifold and check for wire disconnections and dirt clung to it.
When checking and installing the electric heater, replace its gasket with a new part.

LUBRICATING 0.
1. Lower the work equipment to the ground, then stop the engine.
2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.

Fuel control (1 place)

Decelerator
pedal

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MAINTENANCE SERVICE PROCEDURE

CHECK BEFORE STARTING 0.

For the following items, see “CHECK BEFORE STARTING ( 3-56 )“.
Checking with machine monitor
Check coolant level, Add Water
Check fuel level, add fuel
Check oil level in engine oil pan, add Oil
Check oil level in power train case, add oil
Check brake pedal travel
Check dust indicator
Check oil level in hydraulic tank, add Oil
Check electric wirings
Check that lamps light up
Check horn sound
Check back-up alarm sound
Check seat belt for wear or damage
Adjust mirror
Adjust joystick
Adjust armrest

4-37
SERVICE PROCEDURE MAINTENANCE

EVERY 250 HOURS SERVICE 0.

LUBRICATING 0.
1. Lower the work equipment to the ground, then stop the engine.
2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.

(1) Blade lift cylinder support yoke (4 places)

REMARK
These are at the front and rear of the left and right cylin-
ders.

(2) Blade lift cylinder support shaft (2 places)

(3) Blade arm ball joint (4 places)

(4) Brace screw (2 places)

(5) Ripper lift cylinder bottom pin (2 places)

(6) Ripper lift cylinder rod end pin (2 places)
(7) Ripper arm pin (front) (6 places)
(8) Ripper arm pin (rear) (6 places)

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MAINTENANCE SERVICE PROCEDURE

(9) Equalizer bar side shaft (2 places)

(10) Suspension (Equalizer bar center shaft) (1 place)

1) Carry out greasing of the suspension (equalizer bar center

shaft) through the grease fittings marked by arrows.
2) Pump the greasing lever up and down 3 to 5 times.

4-39
SERVICE PROCEDURE MAINTENANCE

CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST 0.

CHECKING 0.
The standard deflection for the drive belt is approx.13 -16 mm
when pressed by thumb (approx.10 kg) at a point midway
Alternator pulley
between the drive pulley and alternator pulley.

Drive pulley

ADJUSTING 0.
1. Loosen bolts (1) and nuts (2), (4), and (5), then turn nut (4)
and adjust the belt tension.
2. After adjusting, tighten bolts and nuts (2), (4), and (5), to
secure alternator (3) in position.
3. Reinstall the cover removed in step 1. Confirm that no part
of the cover touches any turning part of the alternator.

REMARK
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.
If any pulley is defective, ask your Komatsu distributor to replace it.
If any belt has stretched and there is no allowance for adjustment, or if there are cuts or cracks on any
belt, replace both belts at the same time.
When adjusting the V-belt, do not push the tension pulley directly with a steel bar, etc., but put a wood
piece, etc. between the pulley and bar.
After replacing the V-belt, operate for 1 hour, then check and adjust the belt tension again.

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MAINTENANCE SERVICE PROCEDURE

CHECK LEVEL OF BATTERY ELECTROLYTE 0.

Carry out this check before operating the machine.

WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accel-
erate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it
may also cause an explosion.
The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks
near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount
of water and consult a doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER
LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or
corrode other parts.

NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent
the electrolyte from freezing.

Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.

Open battery cover at the left side of the machine.

WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY 0.

If it is possible to check the electrolyte level from the side of the battery, check as follows.
1. Use a wet cloth to clean the area around the electrolyte
level lines and check that the electrolyte level is between
the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.

UPPER LEVEL
LOWER LEVEL

2. If the electrolyte level is below the midway point between

the U.L and L.L lines, remove cap (1) and add distilled water
to the U.L line.
3. After adding distilled water, tighten cap (1) securely.

REMARK
If distilled water is added to above the U.L. line, use a
syringe to lower the level to the U.L. line. Neutralize the
removed fluid with baking soda (sodium bicarbonate),
then flush it away with a large amount of water or consult
your Komatsu distributor or battery maker.

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SERVICE PROCEDURE MAINTENANCE

WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY 0.

If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Remove cap (1) at the top of the battery, look through the
water filler port, and check the electrolyte surface. If the
electrolyte does not reach the sleeve, add distilled water so
that the level reaches the bottom of the sleeve (UPPER
LEVEL line) without fail.

Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.

Correct level Filler port

The electrolyte level is up to the bottom of the
A
sleeve, so the surface tension causes the surface
to rise and the plate appears to be warped. Sleeve A
Upper
Lower
Too low (level)
B The electrolyte level is not up to the bottom of the
sleeve, so the plate appears to be normal.
B

2. After adding distilled water, tighten cap (3) securely.

REMARK
If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom
of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with
a large amount of water or consult your Komatsu distributor or battery maker.

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MAINTENANCE SERVICE PROCEDURE

WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL 0.

If it is possible to use and indicator to check the electrolyte level, follow the instructions given.

CHECK BRAKE PERFORMANCE 0.

WARNING
If the machine moves during the following operation, please contact your Komatsu distributor for repairs
immediately.

NOTICE
Do not place the joystick in the 1st speed position.
Otherwise, it will cause damage to the machine.

Before starting the engine, check that the area around the machine is safe, then do as follows.
1. Start the engine.
2. Start the engine, and after completing the warming-up operation, set fuel control dial (3) to the SLOW position.
3. Set safety lever (1) to the FREE position then operate blade
control lever (6) and ripper control lever (7) to raise the
blade and ripper.
Leave the safety lever (1) to the FREE position.
4. Set parking lever (2) to the FREE position.
Free
5. Depress brake pedal (5), set joystick (4) in FORWARD, then
press the shift up button to enter 2nd speed.
6. Operate fuel control dial (3) and gradually raise the engine
speed to full throttle. (Keep the brake pedal depressed.)
7. Check that the machine does not move. This indicates that Free
brake performance is normal.

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SERVICE PROCEDURE MAINTENANCE

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 0.

1. Open the engine side cover on the left side of the chassis.
2. Remove dipstick (G) and wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.
4. The oil should be between the H and L marks on dipstick
(G). If the oil is below the L mark, add engine oil through
the dipstick insertion port.

5. If the oil is above the H mark, open inspection cover (2) in

the center of the bottom face of the power train case, drain
the excess oil from drain plug (P) of the engine damper
which can be seen towards the front of the machine from
the inspection window, then check the oil level again.

REMARK
Check the oil level while the engine is stopped.
If the machine is inclined, set it in a level position
before checking the oil level.

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MAINTENANCE SERVICE PROCEDURE

EVERY 500 HOURS SERVICE 0.

Maintenance for every 250 hours service should be carried out at the same time.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS
FILTER CARTRIDGE 0.
(including engine by-pass filter cartridge)

WARNING
The oil is at high temperature after the engine has been operated, so never change the oil immediately
after finishing operations. Wait for the oil to cool down before changing it.

Refill capacity: 38 liters

Prepare a socket wrench and filter wrench.
1. Remove the covers at the bottom left at the front of the
machine and on the side face, and put a container directly
underneath to catch the drained oil.
2. Remove drain plug (1) slowly to avoid getting oil on your-
self, and drain the oil.
Take care not to loosen drain valve (1) so much that the
stopper pin in the valve is distorted.
Tightening torque for drain plug (1): 68.6 ± 9.81 N·m
(7 ± 1 kgf·m)
3. Check the drained oil, and if there are excessive metal particles of foreign material, please contact your
Komatsu distributor.
4. Tighten drain valve (1).
5. Using the filter wrench, turn engine oil filter cartridge (2) to
the left and remove it.
6. Clean the filter holder, fill the new filter cartridge with engine
oil, coat the packing surface and thread with engine oil (or
coat it thinly with grease), then install the filter cartridge.
7. When installing the filter cartridge, bring the packing surface
into contact with the filter holder, then tighten a further 3/4
to1 turn.
8. After replacing the filter cartridge, add engine oil through oil
filler port (F) 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 “CHECK OIL LEVEL
IN ENGINE OIL PAN, ADD OIL ( 3-59 )“.

Even if the machine has not been operated for 500 hours,
the oil and filter cartridge must be replaced when the
machine has been operated for 12 months.
In the same way, even if the machine has not been oper-
ated for 12 months, the oil and filter cartridge must be
replaced when the machine has been operated for 500
hours.

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SERVICE PROCEDURE MAINTENANCE

REPLACE FUEL FILTER CARTRIDGE 0.

Prepare a filter wrench and a container to catch the fuel.

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 careful not to let the fuel overflow. It may cause a fire.

NOTICE
Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When
replacing the filter cartridge, always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the
conventional injection pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause prob-
lems with the injection system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the
entry of dirt. If dirt is stuck to any part, use fuel to wash it off completely.

1. Set the container under the filter cartridge to catch the

drained fuel.
2. Close valve (1) of fuel strainer part.
3. Remove the drain plug at the bottom of the filter to drain
fuel.
After draining fuel, tighten the drain plug.
4. Using a filter wrench, turn filter cartridge (2) counterclock-
wise to remove it.
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
of a 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 car-
tridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.
7. Open valve (1) of fuel strainer part and loosen air bleeding
plugs (3).

8. Loosen the knob of priming pump (4), move it up and down, and continue until no more bubbles come out with
the fuel to air bleed plug (3).
9. Tighten air bleed plug (3), push in the knob of priming pump (4), then tighten it.
10.After replacing the filter cartridge, start the engine and check for oil leakage from the filter seal surface.

REMARK
When only the filter cartridge is replaced, it is suffficient that air bleeding is carried out for the filter head
alone. But when the fuel piping is removed, air bleeding should also be carried out for the injection pump
air-bleeding valve.

4-46
MAINTENANCE SERVICE PROCEDURE

REPLACE POWER TRAIN OIL FILTER ELEMENT, STEERING LUBRICATING OIL FILTER ELE-
MENT 0.

WARNING
Before opening the filter cases, 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. Open the left side cover, then loosen 2 bolts at the top of the
inspection cover.

2. Remove bolts (3), pull up cover (4), then take out element
(5).
3. Clean the inside of the case and the removed parts, then
install a new element.
Replace the O-ring also at the same time.

4-47
SERVICE PROCEDURE MAINTENANCE

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL 0.

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 (G) and check whether the final drive
case is filled with oil to lower edge of the plug hole.
3. If the oil level is low, add engine oil through oil level plug
(G).
Before removing the oil level plug (G), remove all the mud
and dirt from around the plug, and be careful not to let any
dirt or mud get in when adding oil.

REPLACE HYDRAURIC TANK BREATHER ELEMENT 0.

WARNING
Replace the element when the oil is cold.
When removing breather cap (1), turn it slowly to release
the internal pressure before removing it.

1. Remove breather cap (1) at the top of the hydraulic tank.

2. Replace element (2) inside the cap.

4-48
MAINTENANCE SERVICE PROCEDURE

EVERY 1000 HOURS SERVICE 0.

Maintenance for every 250 and 500 hours service should be carried out at the same time.

CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER,
SCAVENGING PUMP STRAINER) 0.

WARNING
The oil is at high temperature immediately after operations, so wait for the temperature to go down
before starting the operation.
The undercover is heavy. Do not go directly under the cover when opening or closing it. When remov-
ing bolts (5), carry out the operation at the rear of the point immediately under the cover so that it is
possible to escape at any time.
Prepare the following.

Refill capacity: 60 liters

1. Remove drain cover (1) at the bottom Right of the power

train case, then loosen drain plug (2) and drain the oil.
After draining the oil, tighten drain plug (2).
Do not remove drain plug (2).

4-49
SERVICE PROCEDURE MAINTENANCE

2. Remove inspection cover (2) in the undercover at the bot-

tom rear of the machine as follows.
1) Remove 2 bolts (3) at the Right of machine.
2) Hold cover (3) in position and gradually remove 2 bolts
(4) at the Left of machine. (Rain water may flow out when
doing this.)
3) Lower cover (2) gradually to open it. (The front of the
cover is attached by a hinge.)
If you look up, you can see the strainer.

Front of
machine

3. Remove drain plug (P2) in the strainer cover, and drain the
oil (approx. 4 liters) collected inside the piping.
4. Loosen mounting bolt (5) of the power train strainer, then
remove cover (6).
5. Remove spring (7), then remove strainer (8).
6. Remove any dirt stuck to strainer (8), then wash it in clean
diesel oil or flushing oil. Wash the removed parts and the
inside of the case at the same time.
7. Loosen mounting bolt (9) of the scavenging pump strainer,
then remove cover (10).
8. Remove strainer (11).
9. Remove any dirt stuck to strainer (11), then wash it in clean
diesel oil or flushing oil. Wash the removed parts and the
inside of the case at the same time.
10.Install the strainers to their original position.
11. Replace the power train filter element.
For details, see “REPLACE POWER TRAIN OIL FILTER
ELEMENT, STEERING LUBRICATING OIL FILTER ELE-
MENT ( 4-47 )“.

4-50
MAINTENANCE SERVICE PROCEDURE

12.Refill the specified quantity of engine oil through oil filler (F).
13.After adding the oil, check that the oil is at the specified
level.
For details, see “CHECK OIL LEVEL IN POWER TRAIN
CASE, ADD OIL ( 3-60 )“.
If the spring or strainer are damaged,replace them with new
parts.

CHECK, CLEAN FUEL STRAINER 0.

1. Tighten valve (1).
2. Remove cap (2), and wash the strainer and strainer case.
The strainer forms one unit with the cap.
3. After checking and cleaning, set the strainer in the case,
then tighten cap (2).
4. After installing, open valve (1).

4-51
SERVICE PROCEDURE MAINTENANCE

REPLACE CORROSION RESISTOR CARTRIDGE 0.

WARNING
If the engine has been operated, all parts will be at a high temperature, so never try to replace the car-
tridge immediately after stopping the engine.
Always wait for the engine and other parts to cool down.

Container to catch drained coolant

Prepare a filter wrench for fuel filter element.
1. Turn valve (2) of corrosion resistor (1) as far as the CLOSE
stopper.
2. Set a container to catch the coolant under the cartridge.
3. Using a filter wrench, turn cartridge (3) to the left to remove
it.
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. Turn valve (2) of the cartridge to the OPEN position.
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 prop-
erly.

CHECK TIGHTENING PARTS OF TURBOCHARGER 0.

Please contact your Komatsu distributor to have the tightening portions checked.

4-52
MAINTENANCE SERVICE PROCEDURE

EVERY 2000 HOURS SERVICE 0.

Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time.

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN
HYDRAULIC TANK STRAINER 0.

WARNING
The oil is at high temperature immediately after the machine has been operated. Wait for the oil to
cool down before changing the oil.
When removing the oil filler cap (F), turn it slowly to release the internal pressure, then remove it care-
fully.

Refill capacity: 67 liters

1. Lower the blade and ripper on the ground securely, stop the
engine and slowly turn the cap of oil filler (F) to release the
internal pressure. Then, remove the cap.

2. Remove drain plug (1) at the bottom of the tank and loosen
drain valve (2). After draining the oil, tighten drain plug (1)
and drain valve (2). When loosening drain valve (1), be
careful not to get oil on yourself.

3. Remove bolts (3), then remove cover (4) and take out the
element.
4. Clean the inside of case and removed parts and install a
new element.

5. Remove bolts (5), then remove cover (6) and take out the
strainer.
6. Wash the strainer in clean diesel oil or flushing oil.
7. Install the strainer to its original position.
8. Add engine oil through oil filler port (F) to the specified level.
9. After adding oil, check that the oil is at the specified level.
For details, see “CHECK OIL LEVEL IN HYDRAULIC
TANK, ADD OIL ( 3-62 )“.

4-53
SERVICE PROCEDURE MAINTENANCE

CHANGE OIL IN FINAL DRIVE CASE 0.

WARNING
The oil is at high temperature immediately after the machine has been operated. Wait for the oil to
cool down before starting the operation.
There is danger that oil spouts out due to the internal pressure. When removing the plug, work from
the side, turn the plug slowly to release the internal pressure, and remove it carefully.

Refill capacity: (each) 26 liters

1. Stop the machine so that drain plug (H) is directly at the bot-
tom.
2. After removing oil filler/level plug (G), remove drain plugs
(H) and (1), drain the oil, then tighten the plug again.
3. Add engine oil to the specified level through oil filler level
plug (G).
4. After adding oil, check that the oil is up to to the specified
level. For details, see “CHECK OIL LEVEL IN FINAL
DRIVE CASE, ADD OIL ( 4-48 )“.

4-54
MAINTENANCE SERVICE PROCEDURE

CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER 0.

WARNING
The oil is at high temperature immediately after the machine has been operated. Wait for the oil to
cool down before carrying out maintenance.
The undercover is heavy, so do not go directly under the cover when opening or closing it. When
removing bolts (2) and (3), carry out the operation at the rear of the point immediately under the cover
so that it is possible to escape at any time.

Refill capacity: 1.5 liters

1. Open the engine side cover at the left of the machine; you
can see gauge (G).

2. Remove the undercover (1) at the bottom rear of the chas-

sis as follows.
1) Remove 2 bolts (2) at the Right of machine.
2) Hold cover (1) in position and gradually remove 2 bolts
(3) at the Left of machine. (Rain water may flow out
when doing this.)
3) Lower cover (1) slowly and open it. Drain plug (P) can be
seen at the top.
3. Remove dipstick (G), then remove drain plug (P) and drain
the oil.
After draining the oil,tighten drain plug (P).
4. Add engine oil through the holder of dipstick (G). After add-
ing the oil, insert dipstick (G).
5. Remove any dirt or dust stuck to breather (4), then wash
with clean diesel oil or flushing oil.If it cannot be cleaned
completely, replace with a new part.
6. Then close cover (1).
Right of
machine

4-55
SERVICE PROCEDURE MAINTENANCE

CHECK PIVOT BEARING OIL LEVEL, ADD OIL 0.

1. Remove plug (1).
When removing plug (1), be careful not to let dirt or dust get
it.

2. 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 (1).
Use class CD SAE 30 engine oil regardless of the ambient Oil level
temperature.

A-A Section

CLEAN ENGINE BREATHER ELEMENT 0.

1. Loosen clamp (1), then remove the hose.
2. Then remove breather (2).
3. Rinse the whole breather in diesel oil or flushing oil. Dry
with compressed air, then install it.
4. Check the breather hose, and if any deteriorated oil is stuck
to the inside, replace the hose with a new hose.

REMARK
The engine breather element is at the front end on top of
the engine (behind the radiator).

CHECK ALTERNATOR, STARTING MOTOR 0.

The brush may be worn or the bearing may have run out of grease, so contact your Komatsu distributor for inspec-
tion or repair.
If the engine is started frequently, have this inspection carried out every 1000 hours.

CHECK INJECTOR 0.
Check the color of the exhaust gas visually. If there is any abnormality in the exhaust gas color, contact your
Komatsu distributor for inspection.
For details, see “TROUBLESHOOTING ( 3-107 )“ “Exhaust color is black“.

CHECK VIBRATION DAMPER 0.

Check decrease of damper fluid, dent or out-of-flat. If there is any abnormality, contact Komatsu distributor for
repair.

CLEAN AND CHECK TUTBOCHARGER 0.

Contact your Komatsu distributor for cleaning or inspection.

CHECK PLAY OF TURBOCHARGER ROTOR 0.

Please contact your Komatsu distributor to have the rotor play checked.

4-56
MAINTENANCE SERVICE PROCEDURE

CHECK ENGINE VALVE CLEARANCE, ADJUST 0.

As special tool is required for removing and adjusting the parts, you shall request Komatsu distributor for service.

4-57
SERVICE PROCEDURE MAINTENANCE

EVERY 4000 HOURS SERVICE 0.

Maintenance for every 250, 500, 1000 and 2000 hours service should be carried out at the same time.

CHECK WATER PUMP 0.

Check that there is oil leakage, water, leakage, or clogging of drain hole. If any abnormality is found, contact your
Komatsu distributor for disassemble and repair or replacement.

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER 0.

Check that there is no looseness in the high-pressure clamp mounting bolts (1) - (15) in the drawing on the next
page. Check visually and feel with your finger to check that the rubber has not hardened. If there is any problem,
the problem part must be replaced. In such a case, please contact your Komatsu distributor.

NOTICE
If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is
danger of damage or breakage occurring due to vibration and wear at the connections of high-pressure
piping. Always check that the proper high-pressure piping clamps are correctly installed.

4-58
MAINTENANCE SERVICE PROCEDURE

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 0.

Fuel spray prevention caps (1) - (16) and fuel spray prevention cover (17) are protective parts installed to prevent
fire caused by fuel leaking and spraying out on to high temperature parts of the engine. Check visually that there
are no missing caps or loose bolts, and feel with your finger to check that the rubber has not hardened. If there is
any problem, the problem part must be replaced. In such a case, please contact your Komatsu distributor.

REPLACE INJECTOR ASSEMBLY 0.

Please contact your Komatsu distributor to have the injector nozzle assembly replaced.

4-59
SERVICE PROCEDURE MAINTENANCE

CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER) 0.

Check after the first 4000 hours, and every 1000 hours after
that.
Preparation
Wipe off all the mud that is stuck around portions (A) - (L) of the
work equipment and frame to make it easier to carry out the
check.
Visual check
Carefully check the base material of the steel casting and weld-
ing at portions (A) - (L), and check that there is no damage.
If any cracks or other damage are found, carry out repairs.
Please contact your Komatsu distributor for details of the repair
procedure.

4-60
MAINTENANCE SERVICE PROCEDURE

EVERY 8000 HOURS SERVICE 0.

Maintenance for every 10, 100, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same
time.

REPLACE HIGH-PRESSURE PIPING CLAMP 0.

Please contact your Komatsu distributor to have the engine high-pressure clamp replaced.

REPLACE FUEL SPLAY PREVENTION CAP 0.

Please contact your Komatsu distributor to have the fuel spray prevention cap replaced.

4-61
SERVICE PROCEDURE MAINTENANCE

4-62
SPECIFICATIONS
65
SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS 0.
D85EX-15 D85PX-15
Item Unit
Semi-U tilt dozer Straight tilt dozer

Operating weight (without operator) kg 28,000 (*1) 27,550(*2)

Blade unit weight (including cylinder) kg 3,565 3,345

Ripper unit weight(Multi ripper) kg 2,215 (4,884) -

Drawbar unit weight kg - 176

Name of engine - KOMATSU SA6D125E-3 diesel engine

kW(HP)/
Engine horsepower 179 (240)/1,900
rpm

A Overall length mm 7,224 6,065

B Overall hight mm 3,324 3,361

C Overall width mm 3,635 4,365

Forward km/h 3.6/6.1/10.1 3.6/6.0/10.0

Travel speed (1st/2nd/3rd)
Reverse km/h 4.7/8.0/13.0 4.7/7.9/12.7

*1: Semi-U tilt dozer, multi-shank ripper, ROPS cab, air conditioner
*2: Straight tilt dozer, drawbar, ROPS cab, and air conditioner

5-2
ATTACHMENTS, OPTIONS
76

WARNING
Please read and make sure that you understand the safety
volume before reading this section.
GENERAL PRECAURIONS ATTACHMENTS, OPTIONS

GENERAL PRECAURIONS 0.
PRECAUTIONS RELATED TO SAFETY 0.
If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of
the machine, but will also cause problems with safety.
When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distribu-
tor first.
If you do not contact Komatsu, we cannot accept any responsibility for any accidents or failures.

WARNING
General precautions
Attachments are strong tools. Handle them correctly to prevent serious injury.
Read the operation manual for each attachment carefully, and do not use the machine before you
understand the operation method completely.
If you lose your operation manual, be sure to order another copy from the manufacturer or your
Komatsu distributor.
Place your foot on a pedal only when necessary for prevention of serious injury caused by malfunc-
tion.

Precautions for removal and installation

When removing or installing an attachment, observe the following items and work safely.
Install or remove an attachment on a level and hard place.
When working by two persons or more in cooperation, decide signs and work according to them.
When carrying a heavy part (25 kg) or heavier, use a crane.
When removing a heavy part, be sure to prepare a support for it in advance.
When removing it with a crane, take care of its center of gravity particularly.
It is dangerous to work on a part lifted up with a crane. Be sure to place the part on a stand and check
safety.
When leaving an attachment removed or installing it, place it in a stable position.
Do not stand under a part lifted up with a crane. Stay where your are safe even if the part falls.

NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified per-
son.
For details of removal and installation operations, contact your Komatsu distributor.

6-2
ATTACHMENTS, OPTIONS SELECTION OF TRACK SHOE

SELECTION OF TRACK SHOE 0.

SELECTION OF TRACK SHOES 0.
Select suitable track shoes to match the operating conditions.

METHOD OF SELECTING SHOES 0.

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.

Cate-
Use Precautions when using Track shoe width
gory

Bed-
This shoe can be used for a wide range of work from crushed
rock,
A rock to general civil engineering work such as reclamation of res- 560 mm
normal
idential land. There is no particular limit to its use.
soil

Use this shoe for general soil, such as where the main work is
scraper work and pusher work, reclaiming land for golf courses,
Normal
B or stripping the overburden for coal mines. This shoe cannot be 610 mm
soil
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
C Soft soil into the ground. Do not use this shoe on jobsites where there are 660 mm
rocks in the soil.

6-3
PROCEDURE FOR SELECTING RIPPER POINT ATTACHMENTS, OPTIONS

PROCEDURE FOR SELECTING RIPPER POINT 0.

PROCEDURE FOR SELECTING RIPPER POINT 0.

Procedure (1)

Install standard point (A)

Procedure (2) Yes Is there a high propotion No(less than 70%)

Is wear rapid?
Check wear of quartz in the rock? (Exciiessive generation of heat
No Yes from point (only tip of point wears)
(Whole point
(more then 70%)
wears uniformly)

Install point (B) Install point (C)

Yes Does point break Does point break Yes

Install Install
point (A) when impact force when impact force point (E)
Procedure (3) is applied? is applied?
Check for cracks or
breakage
No No

Hard-
Soft Hard Soft Medium hard soft Medium hard Hard
ness

Type of
Typical General rock Sandstone Basalt, andesite, granite, chert
rock
rock
. Very high propotion of . Fairly high proportion of quartz (40 - 70%)
Fea-
- quartz (70 -95%) point . Does not form seams of layers, so there is excessive generation of heat
tures
wears repidly from the point, the tip wears rapidly, and ripping is difficult.

Point (A) Point (C) Point (D) Point (E)

Point (B)
. Symmetrical shape . Non symmetrical .Symmetrical shape . Symmetrical shape
Fea- . Non-symmetrical shape
. Yellow shape . Red . Red
tures . Yellow
. Short (can be turned and . Red . Long (can be turned . Short (can be turned
. Long
used) . Long and used) and used)

Suit-
able
point
Shape

Part No. 175-78-31230 175-78-34131 175-78-34141 175-78-31293 175-78-31232

6-4
ATTACHMENTS, OPTIONS CAP WITH LOCK, HANDLING

CAP WITH LOCK, HANDLING 0.

METHOD OF OPENING AND CLOSING CAP WITH LOCK 0.
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.

TO OPEN THE CAP 0.

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 Lock Open
to be opened.

Shoulder

Aligning mark

TO LOCK THE CAP 0.

1. Turn the cap into place.
2. Turn the key clockwise and take the key out.

6-5
CAP WITH LOCK, HANDLING ATTACHMENTS, OPTIONS

6-6
INDEX
87
 INDEX

7-2
INDEX

INDEX
9

<A> GENERAL VIEW .................................................. 3-2

ACCUMULATOR, HANDLING ............................ 3-54 GENERAL VIEW OF CONTROLS AND GAUGES
ADJUSTING POSTURE OF WORK EQUIPMENT . 3- 3-3
94 GENERAL VIEW OF MACHINE ...................... 3-2
AIR CONDITIONER ............................................ 3-50 GUIDES TO MAINTENANACE ............................ 4-2
GENERAL LOCATIONS AND FUNCTION OF
CONTROL PANEL ......................................... 3-50
METHOD OF OPERATION ............................ 3-52 <H>
PRECAUTIONS WHEN USING ..................... 3-53 HANDLING OIL, FUEL, COOLANT, AND
ASHTRAY ........................................................... 3-41 PERFORMING OIL CLINIC ............................. 4-5

<B> <I>
BLADE SERIAL NO. PLATE POSITION ............... 1-9 INSTALLATION OF CAB .................................. 3-103
INTRODUCTION .................................................. 1-7

<C>
CAP WITH LOCK, HANDLING ............................. 6-5 <L>
METHOD OF OPENING AND CLOSING CAP LOADING, UNLOADING WORK ...................... 3-100
WITH LOCK ...................................................... 6-5 LOCKING ............................................................ 3-91
CAR STEREO, HANDLING ................................ 3-42 LONG-TERM STORAGE .................................. 3-106
CHECK AFTER FINISHING WORK ................... 3-91 AFTER STORAGE ....................................... 3-106
CHECK AFTER STOPPING ENGINE ................ 3-78 BEFORE STORAGE¥ .................................. 3-106
CHECK BEFORE STARTING ENGINE, ADJUST .. 3- DURING STORAGE .................................... 3-106
55
COLD WEATHER OPERATION ....................... 3-104
<M>
AFTER COLD WEATHER ............................ 3-105
MACHHINE SERIAL NO. PLATE AND POSITION 1-
AFTER COMPLETION OF WORK ............... 3-105
8
PRECAUTIONS FOR LOW TEMTERATURE .... 3-
MAINTENANCE SCHEDULE CHART ................ 4-17
104
METHOD OF LIFTING MACHINE .................... 3-101
CONTROL LEVERS, PEDALS ........................... 3-31
MOVING MACHINE OFF ................................... 3-79

<D> <N>
DOOR OPEN LOCK ........................................... 3-40
NECESSARY INFORMATION ............................. 1-8
DOOR POCKET .................................................. 3-41
Noise emission levels ........................................... 1-5
DUST INDICATOR .............................................. 3-36

<O>
<E>
OPERATION ....................................................... 3-55
ENGINE SERIAL NO. PLATE AND POSITION .... 1-8
OPERATIONS AND CHECKS AFTER STARTING
EXPLANATION OF COMPONENTS .................... 3-5
ENGINE ......................................................... 3-75
OUTLINE OF ELECTRIC SYSTEM ...................... 4-7
<F> OUTLINES OF SERVICE ..................................... 4-5
FOREWORD ......................................................... 1-2
FRONT PANEL ..................................................... 3-5
<P>
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF
PARKING MACHINE .......................................... 3-89
MACHINE ......................................................... 1-7
PERIODIC REPLACEMENT OF SAFETY CRITICAL
FUSE BOX .......................................................... 3-37
PARTS ........................................................... 4-14
FUSIBLE LINK .................................................... 3-39
POSITION OF SERVICE METER ........................ 1-9
PRECAUTIONS FOR LOADING ...................... 3-100
<G> PRECAUTIONS FOR MAINTENANCE .............. 2-23
GENERAL PRECAUTIONS ...........................2-9, 6-2 PRECAUTIONS FOR OPERATION .......... 2-16, 3-88
PRECAUTIONS RELATED TO SAFETY ......... 6-2 BATTERY ....................................................... 2-20

7-3
 INDEX

BEFORE STARTING ENGINE .......................2-16 IF BATTERY IS DISCHARGED ................... 3-109

OPERATION ..................................................2-17 METHOD OF TOWING MACHINE .............. 3-108
TOWING .........................................................2-22 OTHER TROUBLE ....................................... 3-112
TRANSPORTATION ......................................2-20
PRECAUTIONS FOR TRANSPORTATION .....3-102
PROCEDURE FOR SELECTING RIPPER POINT .6- <U>
4 USE OF FUEL, COOLANT AND LUBRICANTS
PROCEDURE FOR SELECTING RIPPER POINT ACCORDING TO AMBIENT TEMPERATURE 4-9
6-4 PROPER SELECTION OF FUEL, COOLANT AND
LUBRICANTS .................................................. 4-9

<R>
REMOVAL OF CAB ..........................................3-102 <V>
RIPPER SERIAL NO. PLATE POSITION .............1-9 Vibration levels ..................................................... 1-5
ROPS, FOPS NO. PLATE POSITION ..................1-9
<W>
<S> WEAR PARTS LIST ............................................. 4-8
SAFETY ................................................................2-2 WORK POSSIBLE USING BULLDOZER ........... 3-92
SAFETY CRITICAL PARTS ................................4-15
SAFETY INFORMATION ......................................1-3
SAFETY LABELS ..................................................2-4
POSITIONS OF SAFETY PICTOGRAMS ........2-4
SASH GLASS INTERMEDIATE LOCK ...............3-40
SELECTION OF TRACK SHOE ...........................6-3
SELECTION OF TRACK SHOES ....................6-3
SERVICE PROCEDURE ....................................4-19
CHECK BEFORE STARTING ........................4-37
EVERY 1000 HOURS SERVICE ....................4-49
EVERY 2000 HOURS SERVICE ....................4-53
EVERY 250 HOURS SERVICE ......................4-38
EVERY 4000 HOURS SERVICE ....................4-58
EVERY 500 HOURS SERVICE ......................4-45
EVERY 8000 HOURS SERVICE ....................4-61
INTIAL 250 HOURS SERVICE(ONLY AFTER THE
FIRST 250 HOURS) .......................................4-19
WHEN REQUIRED .........................................4-19
SHIFTING BETWEEN FORWARD AND REVERSE .
3-84
SHIFTING GEAR ................................................3-82
SPECIFICATIONS ................................................5-2
STANDARD TIGHTENING TORQUES FOR BOLTS
AND NUTS .....................................................4-13
STARTING NEGINE ...........................................3-71
STEERING MACHINE ........................................3-86
STOPPING ENGINE ...........................................3-78
STOPPING MACHINE ........................................3-81
SWITCH ..............................................................3-28

<T>
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR
.........................................................................1-10
TIPS FOR LOMGER UNDERCARRIAGE LIFE ..3-98
TORQUE LIST ....................................................4-13
TRANSPORTATION .........................................3-100
TRANSPORTATION PROCEDURE .................3-100
TRAVELING ON ROADS ..................................3-102
TROUBLESHOOTING ......................................3-107
AFTER RUNNING OUT OF FUEL ...............3-107

7-4
COLOPHON
108
D85EX-15, D85PX-15 BULLDOZER

Form No. EEAM022804

©
2005 KOMATSU

All Right Reserved

Printed in Belgium 09-05