D355c-3 Maintenance and Operation

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FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual 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.
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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
operating the machine.
Location to Keep Operation & Maintenance Manual

Box under left armrest on floor frame
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FOREWORD FOREWORD
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FOREWORD FOREWORD
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
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Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the parking lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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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
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Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous condition
is displayed inside a triangle and the method of avoiding the
hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
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FOREWORD INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Pipe-lifting operations
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
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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.
BREAKING IN THE MACHINE

NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the
machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points when
breaking in the machine.
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.
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NECESSARY INFORMATION FOREWORD
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NO. PLATE AND POSITION

Under the front of the console box on the right side of the operator's seat.
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ENGINE SERIAL NO. PLATE AND POSITION
This is at the rear of the exhaust manifold, on the left side of the engine as seen from the fan.
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FOREWORD NECESSARY INFORMATION
POSITION OF SERVICE METER

This is on the front panel.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Machine serial No.
Distributor name
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Phone/Fax
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CONTENTS FOREWORD
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 7
BREAKING IN THE MACHINE 1- 7
NECESSARY INFORMATION 1- 8
MACHINE SERIAL NO. PLATE AND POSITION 1- 8
ENGINE SERIAL NO. PLATE AND POSITION 1- 8
POSITION OF SERVICE METER 1- 9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 4
POSITIONS OF SAFETY PICTOGRAMS 2- 4
SAFETY LABELS 2- 5
CONTENT AND USE OF WARNING PLATES 2- 7
GENERAL PRECAUTIONS 2- 8
PRECAUTIONS FOR OPERATION 2- 16
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BEFORE STARTING ENGINE 2- 16
OPERATION 2- 18
TRANSPORTATION 2- 21
BATTERY 2- 22
TOWING 2- 24
PRECAUTIONS FOR MAINTENANCE 2- 25
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
FRONT PANEL 3- 5
SWITCHES 3- 14
CONTROL LEVERS, PEDALS 3- 19
FUSE BOX 3- 31
ASHTRAY 3- 32
TOOL BOX 3- 32
AIR CONDITIONER, HANDLING 3- 33
HEATER, HANDLING 3- 37
OPERATION 3- 38
CHECK BEFORE STARTING ENGINE, ADJUST 3- 38
STARTING ENGINE (NORMAL, IN COLD WEATHER) 3- 55
OPERATIONS AND CHECKS AFTER STARTING ENGINE (NORMAL, IN COLD WEATHER) 3- 58
STOPPING ENGINE 3- 61
MOVING MACHINE OFF 3- 62
STOPPING MACHINE 3- 64
SHIFTING GEAR 3- 64
SHIFTING BETWEEN FORWARD AND REVERSE 3- 65
STEERING MACHINE 3- 66
PRECAUTIONS FOR OPERATION 3- 70
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FOREWORD CONTENTS
PARKING MACHINE 3- 72
CHECK AFTER STOPPING ENGINE 3- 74
CHECK AFTER FINISHING WORK 3- 74
LOCKING 3- 74
TIPS FOR LONGER UNDERCARRIAGE LIFE 3- 75
TRANSPORTATION 3- 77
TRANSPORTATION PROCEDURE 3- 77
LOAD LIMITS FOR MACHINE 3- 77
LOADING, UNLOADING WORK 3- 77
PRECAUTIONS FOR LOADING 3- 77
METHOD OF LIFTING MACHINE 3- 78
PRECAUTIONS FOR TRANSPORTATION 3- 78
TRAVELING ON ROADS 3- 78
PROCEDURE FOR REMOVAL AND INSTALLATION OF CAB 3- 79
PROCEDURE FOR REMOVAL AND INSTALLATION OF BOOM 3- 81
PROCEDURE FOR REMOVAL AND INSTALLATION OF COUNTERWEIGHT 3- 83
COLD WEATHER OPERATION 3- 85
PRECAUTIONS FOR LOW TEMPERATURE 3- 85
AFTER COMPLETION OF WORK 3- 87
AFTER COLD WEATHER 3- 87
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LONG-TERM STORAGE 3- 88
BEFORE STORAGE 3- 88
DURING STORAGE 3- 88
AFTER STORAGE 3- 88
TROUBLESHOOTING 3- 89
AFTER RUNNING OUT OF FUEL 3- 89
METHOD OF TOWING MACHINE 3- 89
IF BATTERY IS DISCHARGED 3- 90
OTHER TROUBLE 3- 93
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
OUTLINE OF ELECTRIC SYSTEM 4- 6
WEAR PARTS LIST 4- 7
WEAR PARTS LIST 4- 7
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 8
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 4- 8
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- 14
MAINTENANCE SCHEDULE CHART 4- 15
MAINTENANCE SCHEDULE CHART 4- 15
SERVICE PROCEDURE 4- 17
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 17
WHEN REQUIRED 4- 18
CHECK BEFORE STARTING 4- 33
EVERY 250 HOURS SERVICE 4- 34
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CONTENTS FOREWORD

SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
LIFTING LOAD CAPACITY CURVE 5- 3
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAUTIONS 6- 2
PRECAUTIONS RELATED TO SAFETY 6- 2
USING SEAT BELT 6- 3
HANDLING SEAT BELT 6- 3
SELECTION OF TRACK SHOE 6- 4
SELECTION OF TRACK SHOES 6- 4
CAP WITH LOCK, HANDLING 6- 5
METHOD OF OPENING AND CLOSING CAP WITH LOCK 6- 5
EXTERNAL POWER SOURCE ENGINE PREHEATING HEATER 6- 6
PROCEDURE FOR SETTING UP EXTERNAL POWER SOURCE 6- 6
PROCEDURE FOR HANDLING EXTERNAL POWER SUPPLY 6- 11
INDEX 7- 1
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SAFETY SAFETY
SAFETY
Safety Labels 2- 4
Positions of Safety Pictograms 2- 4
Safety Labels 2- 5
General Precautions
Safety Rules 2- 8
If Abnormalities Are Found 2- 8
Clothing and Personal Protective Items 2- 8
Fire Extinguisher and First Aid Kit 2- 8
Safety Features 2- 8
Keep Machine Clean 2- 9
Inside Operator's Compartment 2- 9
Always Apply Lock When Leaving Operator's Seat 2- 9
Handrails and Steps 2- 10
Mounting and Dismounting 2- 10
No People on Attachments 2- 10
Prevention of Burns 2- 11
Fire Prevention 2- 11
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Action If Fire Occurs 2- 12
Window Washer Liquid 2- 12
Precautions for Attachments 2- 12
Cab Window Glasses 2- 12
Unauthorized Modification 2- 13
Safety at Worksite 2- 13
Working on Loose Ground 2- 13
Do Not Go Close to High-Voltage Cables 2- 14
Ensure Good Visibility 2- 14
Ventilation for Enclosed Areas 2- 14
Checking Signalman's Signals and Signs 2- 15
Be Careful About Asbestos Dust 2- 15
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SAFETY SAFETY
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- 18
Checks Before Operation 2- 18
Precautions for Moving Machine Forward or in Reverse 2- 18
Precautions when Traveling 2- 19
Traveling on Slopes 2- 19
Prohibited Operations 2- 20
Using Brakes 2- 20
Operate Carefully on Snow 2- 20
Parking Machine 2- 20
Transportation 2- 21
Shipping 2- 21
Battery 2- 22
Battery Hazard Prevention 2- 22
Starting with Booster Cable 2- 23
Towing 2- 24
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When Towing 2- 24
Precautions for Maintenance 2- 25

Warning Tag 2- 25
Keep Work Place Clean and Tidy 2- 25
Appoint Leader When Working with Others 2- 25
Stop Engine Before Carrying Out Inspection and Maintenance 2- 26
Two Workers for Maintenance when Engine is Running 2- 27
Proper Tools 2- 27
Personnel 2- 27
Attachments 2- 28
Work Under the Machine 2- 28
Noise 2- 28
Precautions When Using Hammer 2- 28
Repair Welding 2- 28
Removing Battery Terminal 2- 28
Precautions When Using High-Pressure Grease to Adjust Track Tension 2- 29
Do Not Disassemble Recoil Spring 2- 29
Precaution with High-Pressure Oil 2- 29
Handling High-Pressure Hoses 2- 30
Waste Material 2- 30
Maintenance for Air Conditioner 2- 30
Compressed Air 2- 30
Periodic Replacement of Safety Critical Parts 2- 30
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SAFETY LABELS SAFETY
SAFETY LABELS
The following warning signs 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 signs 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
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SAFETY SAFETY LABELS
SAFETY LABELS
(1) Caution for operation, inspection and maintenance
(09651-A0641)
(2) Caution when traveling in reverse (09802-B0750)
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(3) Caution for leaving operator's seat (176-98-43340)
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SAFETY LABELS SAFETY
(4) Caution for high temperature coolant and hydraulic oil

(09653-A0481)
(5) Caution for check and adjust track tension (09657-A0881)
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(6) Caution for handling electric wires (09808-A0881)
The safety label is attached to the back side of the cover of the track adjustment window.
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SAFETY SAFETY LABELS
(7) Caution to stop engine when carrying out inspection and

maintenance (09667-A0481)
(8) Caution about going close when machine is moving

(09806-B1683)
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CONTENT AND USE OF WARNING PLATES

(1) Caution to stop operation when carrying out maintenance work
(09963-A1640)
Hang this from the controls in the operator's compartment.
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GENERAL PRECAUTIONS SAFETY
GENERAL PRECAUTIONS
SAFETY RULES
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
understand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND

If you find any problems 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 problem has been corrected.
CLOTHING AND PERSONAL PROTECTIVE ITEMS

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
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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

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
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.
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SAFETY GENERAL PRECAUTIONS
KEEP MACHINE CLEAN

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).
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

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.
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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

Before standing up from the operator's seat to carry out
adjustments, always set the work equipment lock levers (hook
control, boom control, counterweight control), brake lock lever,
and parking lever to the LOCK position, then stop the engine.
If this is not done and the control levers are touched by accident,
there is danger that the machine or work equipment may
suddenly move and cause a serious personal accident.
Before leaving the machine, always stow the work equipment,

set the work equipment lock levers (hook control, boom control,
counterweight control), brake lock lever, and parking lever to the
LOCK position, then stop the engine. In addition, lock all places,
take the key with you, and leave it in the specified place.
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HANDRAILS AND STEPS

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 getting
on or off the machine.
Never use the parts marked by arrow B when getting on or off
the machine. Use them only when moving along the top of the
track or when checking or carrying out maintenance inside the
side cover, or when filling the tank with oil.
Never jump on or off the machine. In particular, never get on or
off a moving machine. This may cause serious injury.
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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, parking lever, brake lock lever, or
work equipment lock levers (hook control, boom control,
counterweight control) when getting 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

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
Never let anyone ride on the work equipment, or other attachments. There is a hazard of falling and suffering serious
injury.
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PREVENTION OF BURNS
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 coolant 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 pressure before removing
the cap or plug.
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FIRE PREVENTION
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Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly
flammable and can be hazardous. To prevent fire, always
observe the following:
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 chassis,
move any flammable materials to a safe place before
starting.
When washing parts with oil, use a non-flammable oil. Diesel
oil and gasoline may catch fire, so do not use them.
Put greasy rags and other flammable materials into a safe
container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
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Fire caused by accumulation of flammable material.

Prevention of fire around high-temperature parts or electrical parts
Remove any flammable materials, such as dry leaves, chips, paper, or coal dust that are accumulated around
the engine, exhaust manifold, muffler, or battery.
Prevention of fire spreading from outside machine
To prevent fire caused by sparks from fires, remove any flammable materials such as dry leaves, chips, paper,
or coal dust that are accumulated near the cooling system (radiator, oil cooler) or inside the undercover.
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.
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
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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 manual.
ACTION IF FIRE OCCURS

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

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

When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore
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 general
information related to attachments in this manual.
CAB WINDOW GLASSES

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.
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UNAUTHORIZED MODIFICATION
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.
SAFETY AT WORKSITE
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 identify their
locations. Be careful not to sever or damage any of these lines.
Take necessary measures to prevent any unauthorized person
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.
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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

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.
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DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause
serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as
follows.
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. Always
Voltage of Cables Safety Distance
maintain a safe distance (see the table on the right) between the 100 V - 200 V Over 2 m (7 ft)
machine and the electric cable. Check with the local power 6,600 V Over 2 m (7 ft)
company about safe operating procedure before starting 22,000 V Over 3 m (10 ft)
operations. 66,000 V Over 4 m (14 ft)
To prepare for any possible emergencies, wear rubber shoes 154,000 V Over 5 m (17 ft)
and gloves. Lay a rubber sheet on top of the seat, and be careful
187,000 V Over 6 m (20 ft)
not to touch the chassis with any exposed part of your body.
275,000 V Over 7 m (23 ft)
Use a signalman to give warning if the machine approaches too
close to the electric cables. 500,000 V Over 11 m (36 ft)
When carrying out operations near high voltage cables, do not let anyone come close to the machine.
If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should
not leave the operator's compartment until it has been confirmed that the electricity has been shut off.
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Also, do not let anyone come close to the machine.
ENSURE GOOD VISIBILITY

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

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.
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CHECKING SIGNALMAN'S SIGNALS AND SIGNS

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

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

BEFORE STARTING ENGINE
If there is a warning tag hanging from the work equipment control
lever, do not start the engine or touch the levers .
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CHECKS BEFORE STARTING ENGINE
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 damage
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 control
levers are all at the neutral position.
Before starting the engine, check that the parking lever, brake lock lever, and work equipment lock levers (hook
control, boom control, counterweight control) are at the LOCK position.
Check and inspect the actuation of the warning devices.
Check that there are no persons or obstacles above, below, or in the area around the machine.
PRECAUTIONS WHEN STARTING

When starting the engine, sound the horn as a warning.
Start and operate the machine only while seated.
Do not allow anyone apart from the operator to ride on the machine.
Do not short circuit the starting motor circuit to start the engine. Short circuit can cause fire.
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SAFETY PRECAUTIONS FOR OPERATION
PRECAUTIONS IN COLD AREAS

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.
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OPERATION
CHECKS BEFORE OPERATION

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
Check the operation of travel, steering and brake systems, and work equipment control system.
Check and inspect the actuation of the warning devices.
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

Before travelling, check again that there is no one in the surrounding 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 compartment 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.
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If there is an area to the rear of the machine where the visibility 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.
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PRECAUTIONS WHEN TRAVELING

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 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. If the machine has to travel over

an obstacle, travel at low speed. The machine is more stable to
the front and rear than it is to the left and right sides, and is more
likely to tip over to the side, so never travel over any obstacle
that makes the machine tilt strongly to the left or right.
When traveling or carrying out operations, always keep a safe
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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 inside buildings or under bridges or power lines where there are height limits, operate slowly and
be careful not to let the machine or work equipment come into contact with anything.
Be careful not to come to close to the edge of cliffs.
When the machine passes over the top of a hill, the load is suddenly reduced and there is danger that the machine
may increase speed, so reduce the travel speed.
TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always do as follows.
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 traveling
uphill.
When turning on a downhill ground, lower the travel speed.
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PROHIBITED OPERATIONS
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, maximum
using load, etc. to prevent rolling of the machine caused by an overload and disasters caused by breakage of the
work equipment.
USING BRAKES
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

Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine,
and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly
careful when working on slopes.
With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
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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 operations
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
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 moving, then dig
the work equipment into the ground.
After stopping the engine, operate the right work equipment
control lever several times to the RAISE and LOWER positions
to release the remaining pressure in the hydraulic circuit.
Before leaving the machine, always set the parking lever, brake
lock lever, and work equipment lock levers (hook control, boom
control, counterweight control) to the LOCK position, then stop
the engine. In addition, lock all places, take the key with you,
and leave it in the specified place.
Operating posture: See "PARKING MACHINE (PAGE 3-72)"
Places to lock: See "LOCKING (PAGE 3-74)"
Always close the door of the operator's compartment.
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TRANSPORTATION
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
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 support
the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their
instructions.
For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-77)" in the OPERATION section.
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BATTERY
BATTERY HAZARD PREVENTION

Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.
Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.
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 (PAGE
4-36)".
When working with batteries, always wear safety glasses and rubber gloves.
Never smoke or use any flame near the battery.
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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.
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STARTING WITH BOOSTER CABLE

If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
When starting with a booster cable, carry out the starting
operation with two workers (one worker sitting in the operator's
seat and the other working with the battery).
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 starting
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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 (PAGE 3-91).
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TOWING
WHEN TOWING
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 (PAGE 3-89).
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
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by earth-removal work.
When connecting up a towing machine, do not let anyone enter
the area between the towing machine and the equipment 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: 43400 kg (425610 N).
Do not use a broken (A), kinked (B) or frayed (C) wire rope.
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SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR MAINTENANCE

WARNING TAG
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.
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KEEP WORK PLACE CLEAN AND TIDY
Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances
that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out operations safely.
If the work place is not kept claen and tidy, there is the danger that you will trip, slip, or fall over and injure yourself.
APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
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PRECAUTIONS FOR MAINTENANCE SAFETY
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

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.
Operate the work equipment control lever repeatedly 2 or 3
times to the RAISE and LOWER positions to release the
remaining pressure in the hydraulic circuit. Then set the parking
lever, brake lock lever, and work equipment lock levers (hook
control, boom control, counterweight control) to the LOCK
position.
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Put blocks under the track to prevent the machine from moving.
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TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent injury, do not carry out maintenance with the engine
running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and do as
follows.
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.
Set the parking lever, brake lock lever, and work equipment lock
levers (hook control, boom control, counterweight control) to 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.
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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.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
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ATTACHMENTS
Appoint a leader before starting removal or installation
operations 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.
WORK UNDER THE MACHINE

If it is necessary to go under the work equipment or the machine
to carry out service and maintenance, support the work
equipment and machine securely with blocks and stands strong
enough to support the weight of the work equipment and
machine.
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NOISE
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers
or ear plugs while working.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may fly out or metal particles may be
scattered. This may lead to serious injury. Always do as follows.
When hitting solid metal parts, such as pins and bearings, there
is danger of pieces flying off and causing serious personal
injury. Always wear protective glasses, gloves, and other
protective clothing.
When hitting the pins, there is danger of pieces flying off and
injuring people in the surrounding area. Always check that there
is no one near the machine before hitting the pins.
There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment.
There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel
to carry out welding.
REMOVING BATTERY TERMINAL

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the
battery to prevent the flow of current.
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PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION

Grease is pumped into the track tension adjustment system
under high pressure. If the specified procedure for maintenance
is not followed when making adjustment, grease drain valve (1)
may fly out and cause serious injury or damage.
When loosening grease drain valve (1) to loosen track tension,
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).
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DO NOT DISASSEMBLE RECOIL SPRING
Never attempt to disassemble the recoils spring assembly. It contains a spring under high pressure which serves
as a shock absorber for the idler. If it is disassembled by mistake, the spring will fly out and cause serious injury.
When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work.
PRECAUTION WITH HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury, so always do as follows.
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 piping
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 contacts your
eyes directly. If you are hit by a jet of high-pressure oil and suffer
injury to your skin or eyes, wash the place with clean water, and
consult a doctor immediately for medical attention.
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HANDLING HIGH-PRESSURE HOSES

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found,
stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
Damaged or leaking hydraulic fitting.
Frayed or cut covering or exposed reinforcement wire layer.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.
WASTE MATERIAL
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.
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MAINTENANCE FOR AIR CONDITIONER
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite.
Never touch refrigerant.
COMPRESSED AIR
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

For using the machine safely for an extended period of time, replace safety-critical parts like hoses and seat belts
periodically.
Replacement of safety-critical parts: See "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE
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 operating,
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 specified
interval.
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3-1
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GENERAL VIEW OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
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(1) Boom (7) Track shoe

(2) Hook block (8) Winch
(3) Hook wire rope (9) Track frame
(4) Boom wire rope (10) Sheave block
(5) Counterweight (11) Upper sheave block
(6) Cab, operator's compartment
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OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES
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(1) Brake pedal (left) (11) Cab lamp receptacle

(2) Radiator shutter control lever (OP) (12) Gear shift lever
(3) Steering lever (left) (13) Boom control lever
(4) Steering lever (right) (14) Fuel control lever
(5) Brake pedal (right) (15) Boom control lock lever
(6) Deceleration pedal (16) Parking lever
(7) Hook control lever (17) Counterweight control lever
(8) Winch speed selector lever (18) Counterweight control lock lever
(9) Horn switch (19) Brake lock lever
(10) Hook control lock lever
(OP): Option
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GENERAL VIEW OPERATION
FRONT PANEL
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(1) Engine oil pressure gauge (engine oil low (15) Heater temperature control switch
pressure warning lamp) (16) Blower switch (main heater switch combination)
(2) Air cleaner clogging caution lamp (17) Air filter
(3) Engine coolant temperature gauge (18) Wiper switch (front)
(4) Torque converter oil temperature gauge (19) Wiper switch (rear)
(5) Ammeter (20) Ventilator switch (OP)
(6) Starting switch (21) Room lamp
(7) Room lamp switch (22) Cover for cab fuse check
(8) Heater signal (23) Rear lamp switch
(9) Cigarette lighter (24) Lamp switch
(10) Moment indicator advanced warning lamp (OP) (25) Boom working lamp switch
(11) Moment indicator check switch (OP) (26) Rotating lamp switch (OP)
(12) Moment indicator warning lamp (OP) (27) Fog lamp switch (OP)
(13) Vent selector switch (28) Coolant temperature adjustment switch (OP)
(14) Recirc/fresh selector switch
(OP): Option
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OPERATION EXPLANATION OF COMPONENTS
EXPLANATION OF COMPONENTS
The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
FRONT PANEL
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A. Check monitor group
B. Caution monitor group
C. Meter group
A. Check monitor group (see "CHECK MONITOR GROUP (PAGE 3-6)")

Before the engine is started, the basic items among the check before starting items that must be checked are
displayed.
If there is any abnormality, the caution lamp for the location of the abnormality flashes.
NOTICE
When carrying out checks before starting, always see MAINTENANCE or "OPERATION (PAGE 3-38)".
B. Caution monitor group (See "CAUTION MONITOR GROUP (PAGE 3-7)")

These items must be observed when the engine is running. If any abnormality occurs, the item is displayed, so take
action as soon as possible.
C. Meter display (See "METER GROUP (PAGE 3-8)")

This consists of the engine water temperature gauge, torque converter oil temperature gauge, and oil pressure
gauge.
3-5
.
EXPLANATION OF COMPONENTS OPERATION
CHECK MONITOR GROUP
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A(1) Air cleaner clogging caution lamp
AIR CLEANER CLOGGING CAUTION LAMP

This lamp (1) warns operator that the air cleaner is clogged.
If it flashes, stop the engine, check and clean the air cleaner.
3-6
.
CAUTION MONITOR GROUP

CAUTION
If the gauge enters the red range, carry out inspection and maintenance of the appropriate location as soon as possible.
NOTICE
Stop the machine on level ground before carrying out the inspection.
These are items which need to be observed when the engine is running. If any problem occurs, the item needing
immediate repair is displayed. If there is any problem, the problem location on the caution lamp will flash.
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B(1) Ammeter
AMMETER
This meter (1) shows the charging condition.
If the indicator enters the red range, stop the engine and check for
looseness of the alternator V-belt. If any abnormality is found, see
"OTHER TROUBLE (PAGE 3-93)".
3-7
.
METER GROUP
NOTICE
If any meter enters the red range, contact your Komatsu distributor for inspection.
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C(1) Engine coolant temperature gauge C(3) Engine oil pressure gauge
C(2) Torque converter oil temperature gauge
ENGINE COOLANT TEMPERATURE GAUGE

This meter (1) shows the engine coolant temperature.
During normal operations, the indicator should be in the green
range.
If the indicator enters the red range during operation, stop the
machine, run the engine at low idling and wait until the coolant
temperature enters the green range.
NOTICE
If the water temperature gauge often enters the red range, check the radiator for clogging.
3-8
.
TORQUE CONVERTER OIL TEMPERATURE GAUGE

This meter (2) shows the oil temperature at the torque converter
outlet port.
range.
If the indicator enters the red range during operation, stop the
machine, run the engine at low idling and wait until the oil
temperature enters the green range.
ENGINE OIL PRESSURE GAUGE

This meter (3) shows the pressure of the engine lubricating oil.
range.
If the engine is cold, the indicator may go above the green range.
In this case, carry out the warming-up operation until it enters the
green range.
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3-9
.
SWITCHES
These consist of the starting switch, lamp switch, moment indicator check switch, and cigarette lighter.
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(1) Starting switch (3) Moment indicator check switch (OP)
(2) Lamp switch (OP) (4) Cigarette lighter (OP)
(OP): Option
STARTING SWITCH
This switch (1) is used to start or stop the engine.
(A): OFF position
The key can be inserted or withdrawn. Switches for the electrical
system (except room lamp), are all turned off and the engine is
stopped.
(B): ON position
Electric current flows through the charging and lamp circuits. Keep
starting switch key at the ON position while the engine is running.
(C): START position
This is the engine-start position. Keep the key at this position
during cranking. Immediately after starting the engine, release the
key. It will automatically return to the ON position (B).
3 - 10
.
(D): HEAT position

Turn the key to the HEAT position when starting the engine in cold weather.
If the key is held at HEAT position (D), the electric heater becomes hot and the heater signal glows red. When the
heater signal glows red, release the key immediately.
When the key is released, it returns to OFF position (A), so turn it immediately to the START position (C) to start the
engine.
LAMP SWITCH
Use this switch (2) to light up the instrument panel, front lamps, and
side lamp.
Position 1: Instrument panel
Position 2: Instrument panel, front lamps, side lamps
MOMENT INDICATOR CHECK SWITCH
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(if equipped)
Use this switch (3) to check the actuation of the warning device.
When this switch is turned to the ON position, the moment indicator
warning lamp lights up. For details, see "CHECK, INSPECT
MOMENT INDICATOR (PAGE 3-47)".
NOTICE
When the engine is stopped, the boom control lever and hook control lever
cannot be used to move the cylinders even when this switch is turned to
the ON position.
CIGARETTE LIGHTER
(if equipped)
This lighter (4) is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its original
position after a few seconds, so take it out to light your cigarette.
If the cigarette lighter is removed, the socket can be used as a
power source.
NOTICE
This cigarette lighter is 24V. Do not use it as the power supply for 12V
equipment. This will cause failure of the equipment.
The capacity of the cigarette lighter is 120W (24V x 5A).
3 - 11
.
LAMPS
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(1) Moment indicator advanced warning lamp (OP) (3) Heater signal
(2) Moment indicator warning lamp (OP)
(OP): Option
MOMENT INDICATOR ADVANCED WARNING LAMP

(if equipped)
If yellow lamp (1) lights up, raise the boom or reduce the load, then
continue operations.
REMARK
When the lifting capacity (moment) for the working range reaches
approx. 90% of the set limit, moment indicator advanced warning
lamp (1) lights up.
3 - 12
.
MOMENT INDICATOR WARNING LAMP

(if equipped)
If red lamp (2) lights up, stop operations immediately, raise the
boom to reduce the overload, then lower the load. Carry out
inspection and maintenance of the appropriate location.
For details, see "CHECK, INSPECT MOMENT INDICATOR
(PAGE 3-47)".
REMARK
When the lifting capacity (moment) for the working range goes above 90% of the set limit, moment indicator warning
lamp lights up (2) and the alarm buzzer sounds.
HEATER SIGNAL
This lamp (3) lights up red to show that the preheating is
completed.
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3 - 13
.
SWITCHES
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(1) Horn switch (8) Fog lamp switch (OP)
(2) Room lamp switch (9) Vent selector switch
(3) Wiper switch (10) Recirc/fresh selector switch
(4) Rear lamp switch (11) Heater temperature control switch
(5) Boom working lamp switch (OP) (12) Blower switch
(6) Ventilator switch (OP) (13) Coolant temperature adjustment switch (OP)
(7) Rotating lamp switch (OP)
(OP): Option
HORN SWITCH
The horn sounds when button (1) at rear of the hook control lever
at the right side of operator's seat is pressed.
3 - 14
.
ROOM LAMP SWITCH

Use this switch (2) to light up the room lamp.
Position (A): Off
Position (B): On
WIPER SWITCH
Use this switch (3) to operate the wipers.
Position (A): Stopped
Position (B): Operated (slow)
Position (C): Operated (rapid)
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REAR LAMP SWITCH
Use this switch (4) to light up the rear lamp.
Position (A): Off
Position (B): On
BOOM WORKING LAMP SWITCH

(if equipped)
Use this switch (5) to light up the boom working lamp.
Position (A): Off
Position (B): On
3 - 15
.
VENTILATOR SWITCH
(if equipped)
Use this switch (6) to ventilator the cab.
Position (A): Sucks in
Position (B): Stopped
Position (C): Blows out
Before operating the switch, set the ventilator OPEN/CLOSE lever

to the OPEN position (D).
When not using the ventilation, set the OPEN/CLOSE lever to
CLOSED position (E).
ROTATING LAMP SWITCH

(if equipped)
Use this switch (7) to light up the rotating lamp.
Position (A): Off
Position (B): On
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FOG LAMP SWITCH
(if equipped)
Use this switch (8) to light up the fog lamp.
Position (A): Off
Position (B): On
3 - 16
.
VENT SELECTOR SWITCH

Use this switch (9) to select the vent for the warm air.
Knob position Vent Use

Foot vent,
Top Heating
defroster vent
Foot vent, Heating
Center defroster vent, (possible to adjust air flow from
overhead vent vent by position of knob)
Bottom Overhead vent Ventilation
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RECIRC/FRESH SELECTOR SWITCH
Use this switch (10) to select the intake port for air when heating.
RECIRC: Recirculates air inside cab
RECIRC + FRESH: Recirculates air inside cab and also takes
in air from outside
HEATER TEMPERATURE CONTROL SWITCH

Use this switch (11) to adjust the temperature inside the cab when
heating.
The more the knob is moved up, the higher the temperature of
the hot air from the heater vent becomes.
If the knob is moved to the lowest position, the water valve
closes and the heating function stops.
3 - 17
.
BLOWER SWITCH
Use this switch (12) to adjust the air flow when heating. It is also
used as the main heater switch.
The air flow can be adjusted to three stages: Low, Medium,
High
When the knob is set to the OFF position, the electric power is
turned off.
COOLANT TEMPERATURE ADJUSTMENT SWITCH

(if equipped)
Use this switch (13) to adjust the temperature when cooling. It also
functions as the cooler switch.
The more the switch is moved down, the lower the temperature
of the air from the vent becomes.
If the switch is turned to the OFF position, the electric power is
turned off and the cooling function stops.
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3 - 18
.
CONTROL LEVERS, PEDALS
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(1) Fuel control lever (9) Counterweight control lock lever

(2) Gear shift lever (10) Hook control lock lever
(3) Steering levers (11) Boom control lever
(4) Brake pedal (12) Counterweight control lever
(5) Deceleration pedal (13) Hook control lever
(6) Brake lock lever (14) Winch speed selector lever
(7) Parking lever (15) Radiator shutter control lever (OP)
(8) Boom control lock lever
(OP): Option
3 - 19
.
FUEL CONTROL LEVER

Use this lever (1) to adjust the engine speed and output.
(a) Engine stop: Lever pushed beyond low idling position
(b) Low idling (MIN): Lever pulled back to position where operating
effort suddenly becomes heavier
(c) Full speed (MAX): Lever pulled back fully
REMARK
To stop the engine, turn the starting switch to the OFF position.
GEAR SHIFT LEVER

Use this lever (2) to switch the direction of travel between
FORWARD and REVERSE, and to shift the speed range.
Operated back from position (a): FORWARD (3 ranges)
Operated back from position (c): REVERSE (3 ranges)
Positions (a), (b), (c): Neutral
REMARK
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When starting the engine, always check that the gear shift lever is
at the Neutral position. If the gear shift lever is any travel speed
range, the starting motor will not rotate.
STEERING LEVERS
Use these levers (3) to steer the machine.
If the lever is pulled half way, the steering clutch is disengaged and
the machine will turn slowly.
If it is pulled further, the steering brake is applied and the machine
will make a pivot turn.
Right lever (R): Machine turns to right
Left lever (L): Machine turns to left
BRAKE PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.
When this pedal (4) is depressed, the left and right brakes are
applied at the same time.
If the steering lever is pulled halfway and the pedal on the same
side is depressed, the machine will make a pivot turn.
3 - 20
.
DECELERATION PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.
Use this pedal (5) when reducing the engine speed or when
stopping the machine.
Use this pedal to reduce speed when stopping the machine or
shifting between FORWARD and REVERSE.
REMARK
When operating the deceleration pedal, there may be a particular
noise, but there is no problem with quality or durability.
BRAKE LOCK LEVER
WARNING
When stopping the machine and leaving it, always lock the brake pedal.
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Use this lever (6) to lock the brake pedal.
When locking the brake pedal, pull the lever back to LOCK (L)
position and depress the center of the brake pedal. This locks the
brake pedal.
When releasing the brake pedal lock, keep the brake pedal
depressed and push the lever to FREE (F) position.
REMARK
When locking or releasing the brake pedal, always carry out the operation with the engine running.
If the brake is locked when the engine is stopped, the brake boost is not actuated, so the braking force is small
and there is danger that the machine may move. Be particularly careful about this point when parking the
machine on a slope.
PARKING LEVER
WARNING
When stopping the machine and leaving it, always set the parking lever to
the LOCK position.
Use this lever (7) to lock the gear shift lever.
REMARK
Return the gear shift lever to the Neutral position before setting
the parking lever to the LOCK position.
If the parking lever is not at the LOCK position when the engine
is started, the limit switch is actuated and the engine will not
start.
3 - 21
.
BOOM CONTROL LOCK LEVER
WARNING
When standing up from the operator's seat, set the boom control lock
lever securely to the LOCK position.
If it is not locked, and the boom control lever is touched by mistake, it
may cause a serious accident.
If the boom control lock lever is not set securely to the LOCK position,
the lock may not be applied.
Check that the lock lever is in position (L) shown in the diagram on the
right.
When stopping and leaving the machine or when carrying out
maintenance, always set the lever to the LOCK position.
Use this lever (8) to lock the boom control lever.

(L) position: Lock
(F) position: Free
REMARK
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To ensure safety when starting the engine, always set the lock lever to the LOCK position.
COUNTERWEIGHT CONTROL LOCK LEVER
WARNING
When standing up from the operator's seat, set the counterweight
control lock lever securely to the LOCK position.
If it is not locked, and the counterweight control lever is touched by
mistake, it may cause a serious accident.
If the counterweight control lock lever is not set securely to the LOCK
position, the lock may not be applied.
right.
Use this lever (9) to lock the counterweight control lever.

(L) position: Lock
(F) position: Free
REMARK
To ensure safety when starting the engine, always set the parking lever, brake lock lever, and work equipment
control levers (hook control, boom control, counterweight control) to the LOCK position.
3 - 22
.
HOOK CONTROL LOCK LEVER
WARNING
When standing up from the operator's seat, set the hook control lock
lever securely to the LOCK position.
If it is not locked, and the hook control lever is touched by mistake, it
may cause a serious accident.
If the hook control lock lever is not set securely to the LOCK position,
the lock may not be applied.
right.
Use this lever (10) to lock the hook control lever.

(L) position: Lock
(F) position: Free
REMARK
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To ensure safety when starting the engine, always set the lock lever to the LOCK position.
BOOM CONTROL LEVER

Use this lever (11) to operate the boom.
(R) RAISE: Boom goes up
(N) HOLD: Boom stops and brake is applied
(L) LOWER: Boom goes down
REMARK
To prevent the machine from tipping over, the boom lever is
equipped with kickout mechanism. When the boom reaches the
minimum overhang, power is generated to return the lever forcibly
to the HOLD position. Release the lever; do not try to prevent it
from moving.
3 - 23
.
COUNTERWEIGHT CONTROL LEVER

Use this lever (12) to operate the counterweight.
(C) Retract: Counterweight goes up; when lever is released, it
returns to HOLD
(N) HOLD: Counterweight stops and is held in position
(D) Extend: Counterweight goes down; when lever is released, it
returns to HOLD
(F) FLOAT: Counterweight moves freely according to load
REMARK
When retracting or extending the counterweight, when the
cylinder reaches the end of its stroke, return the lever as soon
as possible to the HOLD position.
When there is a large weight on the boom, it is dangerous to
retract the counterweight.
Before operating the counterweight, check carefully that the
surrounding area is safe, then remove safety bolt (1), and
operate the counterweight.
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When not using the counterweight, to ensure safety, lock the
counterweight control lever.
(L) position: Lock
(F) position: Free
3 - 24
.
HOOK CONTROL LEVER

Use this lever (13) to operate the hook.
(R) RAISE: Hook goes up
(N) HOLD: Hook stops and brake is applied
(L) LOWER: Hook goes down
(F) DROP: Hook drops suddenly. This is extremely dangerous, so
use it only in emergencies.
REMARK
When operating the winch (hook, boom), first do as follows.
Set hook control lock lever (10) to the F (FREE) position.
Set boom control lock lever (8) to the F (FREE) position.
Operate winch speed selector lever (14) from the N (Neutral)
position to the L (Low) or H (High) position.
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Inching operation of hook, boom

Run the engine at low speed (1000 rpm) and operate winch speed
selector lever (14) to the L (Low) position. Next, operate hook
control lever (13) or boom control lever (11) rapidly between N
(HOLD) <-> R (RAISE) or N (HOLD) <-> L (LOWER) to move the
load within a range of several mm. By repeating this operation, it
is possible to move the load by the desired amount.
Hook control lever (13) does not work when winch speed selector
lever (14) is at the (N) position.
3 - 25
.
REMARK
When operating the boom and hook at the same time, run the
engine at a speed of at least 800 rpm.
When operating the boom and hook lever, always operate it the
full stroke quickly. After adjusting, return the lever immediately
to the HOLD position.
If the lever is stopped and held midway, load will be applied to
the clutch and brake, so avoid this operation.
When operating the boom, if the drum rotates at high speed
under no load, the wire rope will easily become slack.
Particularly when winding in, the wire rope will not lie smoothly
on the drum, or may break, so limit the engine speed.
If the wire rope is not lying properly on the drum, wind the wire
rope out, apply tension to the wire rope, then wind it in again
properly from the first layer.
The system is designed so that the hook and boom control
levers do not work if the winch speed selector lever is at the N
position, so do not try to operate the levers by force.
The system is designed so that the winch speed selector lever
does not work when the hook and boom levers are being
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operated, so do not try to operate the lever by force.
OVERWIND WARNING SYSTEM

(if equipped)
This system is actuated and the alarm buzzer sounds if distance L
between sheave block (1) and hook block (2) becomes 360 mm
(14.2 in). If this happens, check that the situation is safe, then
lower the hook block to cancel the alarm.
REMARK
When the machine is traveling without the hook control lever or
boom control lever being operated, even if the hook block
sways and alarm switch (3) comes on, no electricity flows, so
this system is not actuated.
When the system is actuated, even if the hook control lever is
at the HOLD position, the moment limiter alarm lamp remains
lighted up and the alarm buzzer continues to sound. When the
hook block is lowered, alarm switch (3) is turned off and the
system stops.
3 - 26
.
HOOK HEIGHT
Use the hook within the height range shown in the graph.
If the hook is wound in too far and the buzzer of the overwind alarm system sounds, return the lever immediately
to the HOLD position to prevent the hook from coming into contact with the top pulley.
When winding out the hook, always leave at least 1.5 loops of wire on the drum.
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HOOK BLOCK HEIGHT
WARNING
When the hook block becomes too high because of overwinding, the wire rope will easily become slack. Particularly when winding
in, the wire rope will not lie smoothly on the drum, or may break, so there is danger that the load may drop. When operating, be
careful to make sure that the wire rope winds properly on to the drum.
If the hook block is raised higher than the specified height, the warning system will be actuated.
3 - 27
.
WEIGHT OF LOAD
WARNING
To protect the machine and ensure safety in the operation, be careful not to overload the hook.
The capacity curve shows the condition when the machine is operating on horizontal, firm ground. The lifting capacity will
drop according to the condition of the road surface, so pay careful attention to the stability of the machine.
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Equipment
Hook, boom line wire rope Number of loops of rope Weight of counterweight [kg (lb)]
Diameter [mm (in)] Cutting load [kg (lb)] Hook Boom
12900 (28445) extended
20 (0.8) 27600 (60858) 8 5
Applicable standard
SAE J 743 (100%) ANSI B 30.14 (85%)
3 - 28
.
CRANE LIFTING LOAD INDICATOR

(if equipped)
This indicates the crane capacity (working range, specified load)
for the boom lifting angle.
During crane operations, the value indicated by the pointer is the

present crane capacity for the boom, so do not carry out operations
above the value indicated by the pointer.
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3 - 29
.
RADIATOR SHUTTER CONTROL LEVER

(if equipped)
Use this lever (15) when opening or closing the radiator shutter.
Raise the bar (release the lock) at the side of the lever, then pull to
close the shutter.
For details, see "RADIATOR SHUTTER (PAGE 3-86)".
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3 - 30
.
FUSE BOX
NOTICE
Before replacing a fuse, be sure to turn starting switch to the OFF position.
Fuses protect the electrical equipment and wiring from burning out.
If a fuse becomes corroded, or white powder can be seen, or a fuse is loose in the holder, replace the fuse.
Replace a fuse with another of the same capacity.
Chassis
Open the fuse inspection cover at the left side of the front panel.
Fuse box I is installed inside.
Equipment installed to cab

Fuse box II is installed to the ceiling.
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FUSE CAPACITY AND NAME OF CIRCUIT
FUSE BOX I
Fuse
No. Circuit
capacity
(1) 10A -
(2) 10A Horn switch, Free fall switch
Engine coolant temperature gauge,
(3) 10A
Torque converter oil temperature gauge
(4) 20A Check lamp, Lamp switch
(5) 10A -
(6) 30A Starting switch, Cigarette lighter
3 - 31
.
FUSE BOX II
Fuse
No. Circuit
capacity
(1) 10A -
(2) 10A Lamp
(3) 10A Rear wiper, Front wiper
(4) 20A Heater switch
(5) 10A Winch drum lamp, Working lamp
(6) 30A Room lamp, Rear lamp
ASHTRAY
This is on the left side of the operator's seat.
Always make sure that you extinguish the cigarette before closing
the lid.
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TOOL BOX
This is inside the left armrest.
Keep the Operation and Maintenance Manual and tools in it.
3 - 32
.
AIR CONDITIONER, HANDLING

(if equipped)
COOLING OPERATION
There are five control switches (1) to (5) on the front panel on the ceiling of the operator's compartment. Operate
the switches as follows to send fresh cool air out from the overhead vents.
Set switches (1) to (3) in the positions shown in the diagram.
Set switches (4) and (5) as desired to give the settings shown in the table below.
RECIRCULATED AIR COOLING

Position of cooler
Position of blower
Use temperature control
switch (5)
switch (4)
Quick cooling Strong cooling High (c)
Normal cooling Medium cooling Medium (b) - low (a)
Weak cooling Weak cooling Low (a)
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FRESH AIR COOLING

If the air inside the operator's compartment is dirty, set RECIRC/FRESH selector switch (2) to the FRESH position
to take in outside air.
The positions for the other switches are the same as for recirculated air cooling. In this position, the air inside the
cab is pressurized to prevent the entry of dust.
3 - 33
.
REMARK
If the cooling effect is insufficient, return RECIRC/FRESH selector switch (2) to the RECIRC position. This will
provide stronger cooling power.
New Freon R134a is used as the refrigerant.
The tightening torque for the air conditioner gas the piping is as shown in the table below.
Thread size (mm) Tightening torque N·m (kgf·m, lbft)

Discharge 22 x 1.5 19.6 to 24.5 (2 to 2.5, 14.5 to 18.1)
Liquid 16 x 1.5 11.8 to 14.7 (1.2 to 1.5, 8.7 to 10.8)
Suction 24 x 1.5 29.4 to 24.3 (3 to 3.5, 21.7 to 25.3)
HEATING OPERATION
the switches as follows to send warm air out from the foot vents and defroster vents (3 at front, 2 at rear).
Set switches (1), (2), and (4) in the positions shown in the diagram.
RECIRCULATED AIR HEATING

Position of heater
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Position of blower
switch (5)
switch (3)
Quick heating Strong heating High (c)
Normal heating Medium heating Medium (b) - low (a)
Weak heating Weak heating Low (a)
3 - 34
.
FRESH AIR HEATING

If the air inside the operator's compartment is dirty, set RECIRC/FRESH selector switch (2) to the FRESH position
to take in outside air.
The positions for the other switches are the same as for recirculated air cooling. In this position, the air inside the
cab is pressurized to prevent the entry of dust.
REMARK
If the heating effect is insufficient, return RECIRC/FRESH selector switch (2) to the RECIRC position. This will
provide stronger heating power.
DEHUMIDIFYING HEATING
the switches as follows to send dehumidified warm air out from the foot vents and defroster vents (3 at front, 2 at
rear).
Set switches (1), (2), and (4) in the positions shown in the diagram.
Position of heater
Position of blower
switch (5)
switch (3)
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Dehumidifying
Strong heating High (c)
heating in winter
Dehumidifying
Medium heating -
heating in Medium (b) - low (a)
weak heating
spring, fall
REMARK
Use this setting in spring or fall, or during the rainy season when the air inside the operator's compartment is humid.
It provides comfortable heating with no problem of the windows misting up.
PRECAUTIONS WHEN USING AIR CONDITIONER
WHEN CARRYING OUT COOLING, VENTILATE THE CAB FROM TIME TO TIME
If you smoke when the cooler is on, the smoke may start to hurt your eyes, so turn the lever to FRESH to remove
the smoke while continuing the cooling.
When the air conditioner is used for long periods, carry out ventilation once every hour.
BE CAREFUL NOT TO COOL TOO MUCH

When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 to 6°C lower than
the outside temperature). This temperature difference is considered to the most suitable for your health, so
always be careful to adjust the temperature properly.
DIRECTION OF VENTS WHEN COOLING

If the vents (left and right) in the middle of the dashboard are turned so that cold air plays directly on the cab door
glass, moisture may condense on the outside of the cab door glass and reduce the visibility. (This occurs
particularly in high temperatures.)
If this happens, turn the vent fully to the rear and raise the air conditioner temperature setting slightly.
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CHECKS DURING OFF-SEASON

Even during the off-season, run the compressor at low speed for several minutes once a week to prevent the loss
of the oil film at the lubricated parts of the compressor. (Run the engine at low speed and set the temperature control
lever at the central position.)
REMARK
When the ambient temperature is low, if the compressor is suddenly run at high speed, it may cause failure of the
compressor. Note that the system is set so that the compressor will not run when the cooler switch is turned on, if
the ambient temperature is less than 2 to 6.5°C (35.6 to 43.7°F).
PROCEDURE FOR REPLACING RECEIVER

Replace the receiver once every two years.
After replacing the receiver, add compressor oil. Turn the receiver at an angle and measure the oil remaining inside
the receiver, then add the same amount of oil (Denso Oil 6) to fill the receiver.
REMARK
Depending on the condition of use, the replacement interval may be shorter.
If the receiver is used when the desiccant has exceeded the water absorption limit, the refrigerant circuit may
become clogged and cause failure of the compressor.
PRECAUTIONS WHEN REPLACING RECEIVER
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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.
CLEANING AIR FILTER

If the air filter for the FRESH or RECIRC air intake becomes clogged, the cooling or heating capacity will drop.
To prevent this, clean the air filter with compressed air once a week.
For details of the cleaning method, see "WHEN REQUIRED (PAGE 4-18)".
CLEANING AIR CONDITIONER CONDENSER FINS

If the air conditioner condenser fins become clogged, the cooling capacity will drop.
Use compressed air to clean the air conditioner condenser fins.
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HEATER, HANDLING
METHOD OF OPERATION
the switches as follows to send warm air out from the foot vents and defroster vents (3 at front, 2 at rear).
Position of heater
Position of blower
switch (4)
switch (3)
Quick heating Strong heating High (c)
Normal heating Medium heating Medium (b) - low (a)
Weak heating Weak heating Low (a)
TO HEAT QUICKLY
Set switches (1), (2), (3), and (4) in the positions shown in the
diagram to carry out heating quickly.
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NOTICE
If recirculated air is used for heating continuously for a long time, the air inside the operator's compartment will become dirty, so
when the operator's compartment becomes warm, always set RECIRC/FRESH selector lever (2) to the FRESH position. In this
position, the air inside the cab is pressurized to prevent the entry of dust.
NORNAL USE
Set each switch to the desired position.
CLEANING AIR FILTER

If the air filter in the recirculated air port or fresh air intake port becomes clogged, the heating capacity will drop.
Use compressed air to clean the air filter once a week.
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OPERATION OPERATION
OPERATION
CHECK BEFORE STARTING ENGINE, ADJUST
WALK-AROUND CHECK
Before starting the engine, look around and under the machine to check for loose nuts and bolts, or leakage of oil,
fuel, or coolant, and check condition of the work equipment and hydraulic system. Also check for loose wiring, play,
and accumulation of dust at places which 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
leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check also for
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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 for cracks, excessive wear, play in wotk equipment, cylinders, linkage, and hoses. If any abnormality is
found, repair it.
2. Remove dirt and debris from around the engine, battery, and radiator
Check for dirt accumulated around the engine or radiator. Also check for flammable material (dry leaves, twigs,
grass, etc.) accumulated around the battery, engine muffler, turbocharger, or other high temperature engine
parts. If any dirt or flammable materials are found, remove them.
3. Check for coolant and oil leakage around the engine

Check for oil leakage from the engine and coolant leaks from the cooling system. If any abnormality is found,
repair it.
4. Check for oil leakage from steering clutch case, final drive case, counterweight tank, hoses, joints
Check that there is no leakage of oil. If any abnormality is found, repair the location of the oil leak.
Check for oil leakage from the undercover and for any signs of oil leakage on the ground surface.
5. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers
If any damage, wear, or oil leakage is found, repair the problem and tighten the bolts.
6. Check for damage to handrail and loose bolts

Repair any damage and tighten any loose bolts.
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OPERATION OPERATION
7. Check for damage to gauges, lamps on the instrument panel, and loose bolts
Check for damage to the panel, gauges, and lamps. Replace any damaged 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.
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OPERATION OPERATION
CHECK BEFORE STARTING

Always check the items in this section before starting the engine each day.
CHECK COOLANT LEVEL, ADD COOLANT
WARNING
Normally, do not open the radiator cap.
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. Remove radiator cap (1) and check that the coolant is above
the bottom surface of the strainer as shown in the diagram on
the right. Add water if the level is low.
2. After adding coolant, tighten the cap securely.
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OPERATION OPERATION
CHECK FUEL LEVEL, ADD FUEL
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If the fuel is spilt, wipe it off completely.
1. Remove the cap, take out dipstick (G), and wipe off all the fuel
from the dipstick.
2. Insert the dipstick again, then take it out and check the fuel
level.
3. After completing work, fill the fuel tank through fuel filler port
(F).
Check the fuel level with the fuel gauge at the fuel filler port.
4. After adding fuel, tighten the cap securely.
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Fuel capacity: 640 liters (169.09 US gal)
REMARK
When dozing on a grade, make sure there is plenty of fuel in the
tank so that the engine fuel line does not become 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.
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OPERATION OPERATION
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.
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. Fully insert dipstick (G) into filler pipe (F), then remove it.
4. The oil level should be between the H and L marks on dipstick

(G).
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If the oil level is below the L mark, add engine oil through oil
filler (F).
5. If the oil is above the H mark, remove drain plug (1), loosen
drain valve (2) to drain the excess oil, then 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 stopping 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.
The dipstick is marked with the levels for ENGINE STOPPED on one side and ENGINE IDLING on the other
side.
It is also possible to check the oil level with the engine idling, but be sure to remember the following points.
Check oil when the engine coolant temperature gauge is within the green range.
Read the dipstick on its reverse side marked with "ENGINE IDLING".
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OPERATION OPERATION
CHECK OIL LEVEL IN STEERING CLUTCH CASE (INCLUDING TRANSMISSION, TORQUE CONVERTER CASE), ADD
OIL
1. Start the engine, run it at idling for 3 - 5 minutes, then check the
oil level with dipstick (G). Take out dipstick (G) and wipe off all
the oil with a cloth.
2. Fully insert dipstick (G) into filler pipe (F), then remove it.
3. The oil level should be between the lines on dipstick (G).
If the oil is below the L line, add engine oil through oil filler port
(F).
REMARK
The oil filler port is on the left, outside the cab.
The dipstick is inside the cover in the floor on the left side of the
operator's seat inside the cab.
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4. If the oil level is above the H line, drain oil as follows.
1) Loosen drain plug (1) at the rear of the machine
undercover, drain the excess oil, then check the oil level
again.
2) If the oil level is correct, insert the dipstick securely.
REMARK
If the machine is at an angle, set it horizontal before carrying out the check.
When the engine is stopped, the oil level is higher, so it is impossible to check the oil level correctly.
CHECK BRAKE PEDAL TRAVEL

Drive the machine, depress the brake pedal, and check that the machine stops.
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OPERATION OPERATION
CHECK OIL LEVEL IN COUNTERWEIGHT TANK, ADD OIL
WARNING
When removing the oil filler port cap, the oil may spurt out, so turn the
cap slowly to release the internal pressure, then remove it carefully.
If too much oil is added and the oil level goes above the H line, stop the
engine, wait for the hydraulic oil to cool down, then drain the excess oil
from drain plug (P).
1. Extend the counterweight and retract the cylinder, set

counterweight lever (2) to the FLOAT (HOLD) position, stop
the engine, wait for approx. 5 minutes, then check that the oil
level is between the H and L lines on 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 spouting out of oil.
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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.
CHECK OIL LEVEL IN WINCH CASE, ADD OIL

1. Stop the engine, wait for approx. 5 minutes, then check that the
oil level is between the lines on dipstick (G).
2. If the oil level is below the L line, add engine oil through oil filler
port (F).
REMARK
When inspecting, if the machine is at an angle, move it to a
horizontal place to carry out the check.
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OPERATION OPERATION
CHECK ELECTRIC WIRING
WARNING
If fuses are frequently blown or if there is a short circuit in the electrical wiring, locate the cause and repair or 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 for 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 wiring. Also check for loose terminals, and tighten any loose
terminals found.
Be sure to check wiring for the battery, starting motor, and alternator.
In addition, if any flammable material is accumulated around the battery, remove it.
For troubleshooting and repairs, contact your Komatsu distributor.
CHECK THAT LAMPS LIGHT UP

1. Turn the starting switch key to the ON position.
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2. Turn the lamp switch (head lamp switch, working lamp switch)
to the ON position and check that the lamps light up.
If the lamps do not light, check for a broken bulb or disconected
wire, contact your Komatsu distributor for repairs.
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OPERATION OPERATION
CHECK HORN SOUND

1. Turn starting switch key to the ON position.
2. Push the horn switch and check that the horn sounds.
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OPERATION OPERATION
CHECK, INSPECT MOMENT INDICATOR

(when equipped with standard boom)
WARNING
If there is any failure in the electrical system or any mechanical parts, the alarm device will not work. Before starting the engine
and after starting the engine, always confirm that the device works properly.
Before starting operations, always check that the moment indicator works properly as follows.
Before starting engine
1. Turn starting switch (1) to the ON position.
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2. Turn moment indicator check switch (2) to the ON position.
3. Check that moment indicator warning lamp (3) lights up and

the buzzer sounds.
If the alarm does not work, there is probably a failure or
disconnection in the electrical system, so carry out repairs to
make it work properly.
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OPERATION OPERATION
LUBRICATING
1. Using a grease pump, apply grease through the grease fittings marked by arrows.
2. After greasing, wipe off all the old grease that is pushed out.
1) Hook and sheave shaft for hook (3 places)
2) Sheave shaft (2 places)
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3) Boom mounting pin (2 places)
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OPERATION OPERATION
4) Boom sheave shaft (4 places)
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5) Counterweight frame mounting pin (6 places)
6) Counterweight cylinder mounting pin (4 places)
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OPERATION OPERATION
ADJUSTMENT
ADJUST MOMENT INDICATOR
WARNING
When adjusting the moment indicator, check at one of the three points on the limit warning curve in the movement characteristics
graph.
Fix the primer block securely.
Movement characteristics graph
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REMARK
The moment indicator warning lamp (red) on the front panel lights up when the moment indicator is actuated on the
limit warning curve in the movement characteristics graph.
Judge if the set values of the moment indicator are above or below
Adjustment Working
the standard values by checking if the moment indicator warning Load (t)
points radius (m)
lamp lights up red when lifting operations are carried out at the 3
A 3.0 34.0
adjustment points (A, B, C).
B 5.0 20.0
Flashes: Set value is lower than standard C 7.0 14.0
Lights up: Set value is higher than standard
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OPERATION OPERATION
PROCEDURE FOR ADJUSTMENT
Turn 4 lock bolts (2) holding primary block (1) 2 turns to loosen.
(To prevent the pulley from falling, do not loosen more than 2
turns.)
If moment indicator is actuated at a value lower than standard value (inside of performance curve)
1. Loosen locknut (3) and adjustment bolt B (4).
2. Turn adjustment bolt A (5) to move primary block (1) towards
the front of the machine.
3. When the moment indicator warning lamp (red) on the front
panel lights up, tighten bolt B (4).
4. Tighten locknut (3), then tighten lock bolt (2). This completes
the adjustment.
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If moment indicator is actuated at a value higher than standard value (outside of performance curve)
1. Loosen locknut (3) and adjustment bolt A (5).
2. Turn adjustment bolt B (4) to move primary block (1) towards
the rear of the machine.
3. When the moment indicator warning lamp (red) on the front
panel lights up, tighten bolt A (5).
4. Tighten locknut (3), then tighten lock bolt (2). This completes
the adjustment.
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OPERATION OPERATION
ADJUSTING OPERATOR'S SEAT
WARNING
Carry out adjustment before starting operations and when the operators change shifts.
Adjust the seat so that you can depress the brake pedal fully with your back pressed against the backrest of the operator's seat.
(A) Fore-and-aft adjustment

Pull lever (1), set the seat to a position where it is easy to operate,
then release the lever.
Fore-aft adjustment: 160 mm (6.3 in) (8 stages)
(B) Weight adjustment of seat

Turn knob (2) under the seat to match the weight adjustment scale
with your own weight.
This will provide you with a comfortable ride.
Weight adjustment: 50 - 130 kg (110 - 287 lb)
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(C) Adjust reclining angle
Move lever (3) to the rear, set the seat back to the desired position, then release the lever.
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.
(D) Seat angle

Pull up lever (4) to adjust the angle at the front of the seat. (5 stages)
To raise the height at the front of the seat, keep the lever pulled up and apply your weight to the back of the seat.
To lower the height at the front of the seat, keep the lever pulled up and apply your weight to the front of the seat.
Pull up lever (5) to adjust the angle at the rear of the seat. (5 stages)
To raise the height at the rear of the seat, keep the lever pulled up and remove your weight from the seat.
To lower the height at the rear of the seat, keep the lever pulled up and apply your weight to the rear portion of
the seat.
(E) Height adjustment

To adjust the height, pull up levers (4) and (5) in turn to adjust the angle at the front and rear. After reaching the
desired height, release the levers and lock them in position.
(Height adjustment: 5 stages, 60 mm (2.4 in))
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OPERATION OPERATION
OPERATIONS AND CHECKS BEFORE STARTING ENGINE

WARNING
When starting the engine, always check that the parking lever, brake
lock lever, and work equipment control levers (hook control, boom
control, counterweight control) are set securely to the LOCK position.
If the work equipment control levers are touched by accident when the
engine starts, the work equipment may move unexpectedly, and this
may lead to serious personal injury.
Before standing up from the operator's seat, regardless of whether the
engine is running or not, always set the work equipment lock levers
(hook control, boom control, counterweight control), brake lock lever,
and parking lever to the LOCK position, then stop the engine.
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1. Check that brake lock lever (1) is at the LOCK position.
If it is not at the LOCK position, the engine will not start.
2. Check that gear shift lever (2) is locked at the N position.
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OPERATION OPERATION
3. Check that boom control lever (3), hook control lever (4), winch
speed lever (5), and counterweight control lever (6) are locked
at the HOLD position.
4. Set fuel control lever (7) at the engine stop position.
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OPERATION OPERATION
STARTING ENGINE (NORMAL, IN COLD WEATHER)
NORMAL STARTING
WARNING
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 confined spaces, be
particularly careful to ensure good ventilation.
NOTICE
Do not keep the starting motor rotating continuously for more than 20
seconds.
If the engine will not start, wait for at least 2 minutes before trying to start
the engine again.
1. Pull fuel control lever (1) to the low idling position.
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2. Turn the key of starting switch (2) to the START position.
3. When engine is started, release the key of starting switch (2)

and the key will return automatically to ON.
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OPERATION OPERATION
STARTING IN COLD WEATHER

WARNING
Check that there are no persons or obstacles in the surrounding area,
then sound the horn and start the engine.
Never use starting aid fluids as they may cause explosions.
Exhaust gas is toxic. When starting the engine in confined spaces, be
particularly careful to ensure good ventilation.
NOTICE
Do not keep the starting motor rotating continuously for more than 20
seconds.
If the engine fails to start, repeat steps 3 and 4 after waiting for about 2
minutes.
1. Set fuel control lever (1) to a position midway between low

idling and full speed.
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2. Turn the key in starting switch (2) to the START position, rotate
the starting motor for 10 seconds, then return the key to the
OFF position.
3. Return fuel control lever (1) to the low idling position.
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OPERATION OPERATION
4. Turn starting switch (2) to the HEAT position. Heater signal (3)
will light up.
(Preheating is automatically started.)
5. Wait until heater signal (3) goes out. (Preheating will be
completed in approx. 12 seconds, and the lamp will go out.)
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6. When heater signal (3) goes out, turn starting switch (2) to the
START position and start the engine.
Heater signal (3) stays lighted up for the times shown in the
table below according to the ambient temperature.
Ambient temperature Lighting up time

0 to 10 °C (32 to 50°F) 0 to 15 sec.
- 10 to - 20 °C (14 to -4°F) 15 to 30 sec.
- 20 to - 30 °C (-4 to -22°F) 30 to 50 sec.
7. When the engine starts, release the key in starting switch (2) (it
will return automatically to the ON position), then carry out the
warming-up operation.
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OPERATION OPERATION
OPERATIONS AND CHECKS AFTER STARTING ENGINE (NORMAL, IN COLD WEATHER)
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 sufficiently warming up the machine, the response of the work equipment to the
movement of the control levers will be slow and may not move as the operator desires. Always warm the machine to full
operating temperature, particulary in cold areas.
WARMING UP OPERATIONS
NOTICE
Do not accelerate the engine suddenly before the warming-up operation
is completed.
Do not run the engine under no load at low idling or high idling
continuously for more than 20 minutes. Running the engine for an
excessively long time will cause pollution of the environment, and will
also have an adverse effect on the turbocharger and other internal parts
of the engine. If it is necessary to run longer at idling, apply a load from
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time to time and run at a mid-range speed.
If engine oil pressure gauge (2) enters the red range, stop the engine
and check.
1. Set fuel control lever (1) at a position midway between the low
idling and full speed positions to set the engine to a mid-range
speed, and run under no load for approx. 5 minutes
(warming-up operation).
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OPERATION OPERATION
2. After completing the warming-up operation, check that the

gauges and caution lamps work properly. If any abnormality is
found, carry out maintenance and repairs.
Run the engine under a light load until engine water
temperature gauge (3) enters the green range.
Check that the indicator of ammeter (4) is in the green range.
3. Check for abnormal exhaust gas color, noise, or vibration. If
any abnormality is found, contact your Komatsu distributor.
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IN COLD AREAS
NOTICE
.com
If the fuel control lever is pulled suddenly immediately after the engine
starts, the engine oil pressure gauge may go above the green range. Do
not pull the fuel control lever to the full speed position until the indicator
enters the green range.
1. Set fuel control lever (1) at a position midway between the low
idling and full speed positions to set the engine to a mid-range
speed, and run under no load for approx. 10 minutes
(warming-up operation).
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OPERATION OPERATION
2. Operate counterweight control lever (2) to RETRACT, keep

the counterweight in a raised position, and relieve the circuit
intermittently for 10 minutes.
3. Finally, actuate the counterweight cylinder 2 or 3 times. If the
temperature of the oil in the counterweight tank is not raised
sufficiently, the response of the counterweight may be
delayed.
4. After completing the warming-up operation, check that the

gauges and caution lamps work properly. If any abnormality is
found, carry out maintenance and repairs.
Run the engine under a light load until engine water
temperature gauge (3) enters the green range.
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5. Check that the indicator of ammeter (4) is in the green range.
6. Check that the indicator of tool converter oil temperature gauge

(5) is in the green range.
Check for abnormal exhaust gas color, noise, or vibration. If
any abnormality is found, contact your Komatsu distributor.
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OPERATION OPERATION
STOPPING ENGINE
NOTICE
If the engine is stopped without allowing it to cool down, there is danger
that the service life of various parts of the engine will be reduced. Except
in emergencies, never stop the engine suddenly.
If the engine overheats, do not stop it suddenly. Run it at low speed to
allow it to cool down gradually, then stop it.
1. Set fuel control lever (1) to the STOP position and stop the
engine.
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2. Turn the key in starting switch (2) to the OFF position, then
remove the key.
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OPERATION OPERATION
MOVING MACHINE OFF

WARNING
When moving the machine off, check first that the area around the
machine is safe, then sound the horn before moving off.
Do not allow anyone to enter the area around the machine.
The area at the rear of the machine is a blind spot, so be particularly
careful when traveling in reverse.
When starting the machine off on a slope, always keep brake pedal (2)
depressed, even after setting brake lock lever (1) to the FREE position.
When starting off up a steep slope, pull fuel control lever (3) fully to run
the engine at full speed. Keep brake pedal (2) and decelerator pedal (9)
depressed, set gear shift lever (4) to the desired position, then slowly
release brake pedal (2). When the machine picks up speed, release
decelerator pedal (9) slowly.
1. Keep brake pedal (2) depressed and set brake lock lever (1) to
the FREE position.
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2. Set boom control lock lever (7) of boom control lever (5) and
counterweight control lock lever (8) of counterweight control
lever (6) to the FREE position.
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OPERATION OPERATION
3. Set fuel control lever (3) to the FULL position to raise the
engine speed, then depress decelerator pedal (9) fully.
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4. Set parking lever to the FREE (F) position and gear shift lever
(4) to the F (FORWARD) or R (REVERSE) and the desired
speed range, then gradually release decelerator pedal (9) and
move the machine off.
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OPERATION OPERATION
STOPPING MACHINE
WARNING
Avoid stopping suddenly. As far as possible, leave room when
stopping.
Do not park the machine on a slope. If the machine has to be parked on
a slope, set brake lock lever (2) to the lock position and put blocks under
the tracks to prevent the machine from moving.
If the work equipment control levers (hook control, boom control,
counterweight control) are touched by accident, the work equipment
may move unexpectedly, and this may lead to serious personal injury.
Before standing up from the operator's seat, always set the work
equipment lock levers (hook control, boom control, counterweight
control) securely to the LOCK position.
1. Depress brake pedal (1) to apply the brake, then set brake lock
lever (2) securely to the LOCK position.
NOTICE
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If the engine speed is high and the travel speed is also high, the brake discs
may generate a slipping sound when the brake pedal is depressed.
Normally, depress decelerator pedal (3) to reduce the engine speed and
machine travel speed before depressing the brake pedal.
2. Return the gear shift lever to the N position.
SHIFTING GEAR
The machine does not have to be stopped to shift gears.
1. To shift gear, operate the gear shift lever to the desired speed
range.
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OPERATION OPERATION
SHIFTING BETWEEN FORWARD AND REVERSE

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 switching between
FORWARD and REVERSE.
To increase safety, operator comfort, and the life of the transmission, leave
the engine running at full speed, and always depress the decelerator pedal
to lower the engine speed.
1. Depress decelerator pedal (2) and reduce the engine speed.
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2. Return gear shift lever (1) to the N position, then shift it to the
desired position.
3. Release decelerator pedal (2) and raise the engine speed.
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OPERATION OPERATION
STEERING MACHINE
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
When traveling, pull left steering lever (1) to turn left.
To turn right, pull right steering lever (1).
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TURNING GRADUALLY TO LEFT WHILE TRAVELING FORWARD
Pull the left steering lever halfway to disengage the steering clutch
and turn gradually to the left.
To turn gradually to the right, pull the right steering lever halfway.
Use the same procedure when traveling in reverse.
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OPERATION OPERATION
MAKING SHARP TURNS TO LEFT WHILE TRAVELING FORWARD

Pull the left steering lever fully to disengage the steering clutch and
engage the steering brake to make a pivot turn to the left.
REMARK
To make a pivot turn to the right, pull the right steering lever fully.
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OPERATION OPERATION
TURNING WHILE DESCENDING A SLOPE

WARNING
On downhill slopes where the machine travels under its own weight, or on downhill slopes where the machine is being pushed
by towed machine, there may be cross steering, so do as follows.
REMARK
Cross steering means the phenomenon that the machine turns in the opposite direction to the actual steering
direction.
TURNING GRADUALLY TO LEFT WHILE TRAVELING FORWARD

Pull the right steering lever halfway to turn gradually to the left.
REMARK
To turn gradually to the right, pull the left steering lever halfway.
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OPERATION OPERATION
MAKING SHARP TURNS TO LEFT WHILE TRAVELING FORWARD

Pull the left steering lever fully to make a pivot turn to the left. (The
steering brake is engaged, so there is no cross steering.)
REMARK
To make a pivot turn to the right, pull the right steering lever fully.
(The steering brake is engaged, so there is no cross steering.)
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OPERATION OPERATION
PRECAUTIONS FOR OPERATION
PAY ATTENTION TO GAUGES

If the torque converter oil temperature gauge enters the red range during operations, reduce the load and wait for
the oil temperature to go down.
METHOD OF USING STEERING CLUTCH

If the steering clutch one side is used frequently or if many gradual turns are made with steering clutch half-engaged,
the steering clutch will wear out in a short time. Design the travel road well and steer the machine properly.
HANDLING LONG BOOM

When the long boom is installed, be careful not to apply a diagonal load to the tip of the boom.
Do not use the long boom for diagonal loads or for operations on slopes.
(The stability of the machine and the strength of the boom drops.)
PERMISSIBLE WATER DEPTH

When operating in water, always keep top surface of the track
frame above the surface of the water.
Also, be careful that the engine cooling fan will not come in contact
with water. The fan can be damaged.
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PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS
METHOD OF USING DECELERATOR PEDAL

When stepping on the decelerator pedal while going uphill, climbing ability will be reduced and the machine will stop.
Furthermore, the engine may stall.
USE ENGINE AS BRAKE

When traveling downhill, place the gear shift lever in a low speed range, run the engine at low speed and use the
braking force of the engine.
Do not set the steering lever at the N position.
When traveling down a hill with a grade of more than 15 degrees, use R1 or F1.
BRAKING WHEN TRAVELING DOWNHILL

While descending a slope using the engine as a brake, also apply the brakes.
Failure to brake may result in overrunning, causing engine trouble.
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OPERATION OPERATION
PRECAUTIONS ON SLOPE
BE CAREFUL OF FUEL LEVEL

If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle
of the machine or the swaying of the machine. 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

When operating machine on sloped areas of more than 20°, fill all appropriate components with oil to H level.
PRECAUTIONS WHEN ENGINE STOPS ON SLOPE

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

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
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Always depress the decelerator pedal to lower the engine speed before actuating the brakes.
PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS

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
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.
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OPERATION OPERATION
PARKING MACHINE
WARNING
Avoid stopping suddenly. As far as possible, leave room when
stopping.
When stopping the machine, select flat hard ground and avoid
dangerous places.
Do not park the machine on a slope.
If the work equipment control levers (hook control, boom control,
counterweight control) are touched by accident, the work equipment
may move unexpectedly, and this may lead to serious personal injury.
Before standing up from the operator's seat, always set the work
equipment lock levers (hook control, boom control, counterweight
control) securely to the LOCK position.
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
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brake disc may make a slipping sound. Normally, depress decelerator
pedal (3) to reduce the engine speed and travel speed before depressing
the brake.
2. Set gear shift lever (2) at the neutral position.
3. Operate the parking lever to set the gear shift lever to the
LOCK position (L).
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OPERATION OPERATION
4. Operate brake lock lever (4) to lock the brake.
5. Set boom control lever (5) and counterweight control lever (6)
to the HOLD position.
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6. Set boom control lock lever (7) of boom control lever (5) and
counterweight control lock lever (8) of counterweight control
lever (6) to the FREE position.
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OPERATION OPERATION
CHECK AFTER STOPPING ENGINE

1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for
any leakage of oil or coolant. If any problem 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.
CHECK AFTER FINISHING WORK

Use the meters and caution lamps to check the engine water
temperature, engine oil pressure, and torque converter oil
temperature.
LOCKING
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To prevent vandalism, there are locks at the following places.
Places that can be locked with the starting switch key.
Left and right engine side covers (left side: 1 place; right side: 2
places)
Cab door opener
Caps with lock (if equipped)
Radiator cap
Fuel tank cap
Counterweight tank cap
Steering clutch case oil filler pipe cap
Battery inspection cover
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OPERATION OPERATION
TIPS FOR LONGER UNDERCARRIAGE LIFE

Undercarriage life greatly varies depending on operation method, inspection and maintenance. For most efficient
operation, keep the following point in mind.
OPERATION METHOD
Select the track shoe that best suits the type of soil to be encountered in service.
Consult your Komatsu distributor when selecting track shoes.
Do not allow shoe slipage to occur during operation. If slipage occurs, reduce load to the blade until slipping stops.
Avoid sudden starts, acceleration or stops, unnecessary 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 stopping the
machine on a slope, the machine should face toward the top of
the slope.
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INSPECTION AND ADJUSTING
Properly adjust track tension.
Tension should be measured at clearance (A) shown in the
diagram - usually 20 to 30 mm (0.8 to 1.2 in) at this point. For
rocky terrain, tighten tracks slightly. In clay or sandy areas,
slightly loosen them. (For inspection and adjustment
procedures, refer to "CHECK TRACK TENSION (PAGE 4-23)").
Check idler rollers for oil leakage as well as for loose bolts and
nuts. If any trouble is detected, repair immediately.
Check clearance B between idler guided plate (1) and track

frame (2). If clearance B becomes too large, it will cause side
play of the idler and the track may come off. (For details of the
method for inspection and adjustment, see "ADJUST IDLER
CLEARANCE (PAGE 4-25)".)
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OPERATION OPERATION
INSPECTION AND REPAIR

Frequent inspection and prompt repair will reduce repair costs.
The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Perform
periodical inspection and contact the Komatsu distributor in your area when machine has approached repairable
limits and reversing limits.
MEASURING HEIGHT OF GROUSER

After taking up slack in track shoes, measure height at center of
shoe as shown below.
Standard height (h): 88 mm (3.5 in)
Repair limits: 25 mm (1.0 in)
MEASURING OUTSIDE DIAMETER OF TRACK ROLLER

1. Measure height (size C) of link tread as shown.
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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 height (h): 220 mm (8.7 in)
Repair limits: 244 mm (9.6 in)
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OPERATION TRANSPORTATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
A trailer should be used for transporting the machine.
LOAD LIMITS FOR MACHINE

For details, please consult your Komatsu distributor.
LOADING, UNLOADING WORK

WARNING
Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely loaded and unloaded.
If the ramp sags appreciably, reinforce it with blocks, etc.
When loading and unloading the machine, park the trailer on a flat firm roadbed. Keep a fairly long distance between the road
shoulder and the machine.
Remove the mud from the undercarriage to prevent the machine from slipping to the side on slopes.
Be sure the ramp surface is clean and free of grease, oil, ice and loose materials.
Never change the direction of travel when on the ramps. If it is necessary to change direction, drive off the ramps and correct
the direction, then drive on to the ramps again.
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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 the
machine at slow travel.
3. Load the machine correctly in the specified position on the
trailer.
PRECAUTIONS FOR LOADING

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 all work equipment control levers securely with the work equipment lock levers (hook control, boom control,
counterweight control).
3. Set the parking lever and brake lock lever to the LOCK position.
4. Turn the starting switch to the OFF position stopping the engine, then remove the key.
5. Lock the cab door, left and right engine side covers, and the battery inspection cover.
6. Place blocks under both ends of the tracks to prevent the machine from moving during transportation, and
secure the machine with chains or wire rope of suitable strength.
Be particulary careful to secure the machine in position so it does not slip to the side.
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TRANSPORTATION OPERATION
METHOD OF LIFTING MACHINE

WARNING
Never perform lifting operations with any person on the machine.
Always make sure that the wire rope (cable) 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, perform the operation on flat ground as

follows:
1. Stop the engine, then set the parking lever, brake lock lever,
and work equipment lock levers (hook control, boom control,
counterweight control) to the LOCK position.
2. Set the lifting position for the machine as shown in the diagram
on the right.
NOTICE
The lifting procedure applies to machines with standard specifications.
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The method of lifting differs according to attachments and options actually
installed on the machine. For the proper lifting procedures, contact your
For details of the weight, see "SPECIFICATIONS (PAGE

5-2)".
PRECAUTIONS FOR TRANSPORTATION

WARNING
Determine the route for transporting the machine by taking 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
When traveling on 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.
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PROCEDURE FOR REMOVAL AND INSTALLATION OF CAB

WARNING
Be sure to use lifting equipment of ample strength.
When removing the cab for transportation of the machine, do as follows.
REMOVAL OF CAB
1. Disconnect cab power source plug (1) (right side of dashboard)
and the machine socket.
2. Remove the hot water heater piping.
3. Remove 4 bolts (2) and 6 bolts (3), then use a crane to lift off
cab assembly (4).
Weight of cab assembly: 670 kg (1477 lb)
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INSTALLATION OF CAB
1. Stick seat (5) to the floor frame.
In cold weather, the adhesive effect drops, so warm the seat
before using it.
2. Stick seal (6) to cab assembly (4).
3. Using bolts (1) and (2), install the cab assembly to the floor
frame.
4. Connect the hot water heater piping to the cab.
5. Connect the cab power source plug to the machine socket.
Open the valve in the hot water circuit for the hot water heater.
Check the operation of the electrical equipment inside the cab.
In addition, check the operation of the hot water heater, then
check the cooling water level in the radiator and add water if
necessary.
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PROCEDURE FOR REMOVAL AND INSTALLATION OF BOOM
REMOVAL OF BOOM, HOOK BLOCK, SHEAVE BLOCK

1. Move the pulley at the hook block end and stop the boom.
2. Set the boom on a stand so that it pushes the block slightly.
Be careful not to let the wire bite into the bottom of the block.
3. Remove the hook block and sheave block from the boom.
4. Wind the wire rope onto the winch.
5. 5. Remove the boom from the machine.
Weight of boom [7.5 m (24 ft 7 in)]: 1530 kg (3374 lb)
Weight of boom [8.5 m (27 ft 11 in)]: 1730 kg (3815 lb)
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INSTALLATION OF BOOM, HOOK BLOCK, SHEAVE BLOCK
1. Install the boom.
2. Install the upper sheave block to the boom.
3. Fit the boom RAISE wire and hook wire.
For details of fitting the wire rope, see "FITTING WIRE ROPE (PAGE 3-82)".
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FITTING WIRE ROPE

Fit the boom RAISE wire and hook wire as follows.
i) Boom RAISE wire

1. Fit the wire rope securely to the boom with a wedge, then apply
tension and wind in the wire rope.
2. Take wire rope (5) from the drum and pass it from the front face
to the rear face through the bottom stage sheave of upper
sheave block (2).
3. Take wire rope (6) from upper sheave block (2) and pass it from
the rear face to the front face through the bottom stage sheave
of lower sheave block (1).
4. Pass wire rope (7) through the top sheave of upper sheave
block (2).
5. Pass wire rope (8) through the top sheave of lower sheave
block (1).
6. After winding in wire rope (9), bring it in to wedge pocket (3) at
the top plate of upper sheave block (2), and secure with wedge
(4). (Extend the end of the wire rope approx. 10 cm more than
the wedge.) Check that the wire rope is fixed in position, then
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fix the end of the wire rope with the wire clip.
ii) Hook
1. Fit the wire rope securely to the hook drum with a wedge, then
apply tension and wind in the wire rope.
2. Pass the wire rope from the drum through idler sheave (1), then
take it from the bottom of both boom stays to sheave block (2)
at the top end of the boom.
3. Pass the wire rope through the sheave at the front of sheave
block (2) and hook block (3) in turn to the rear sheave, then from
sheave block (2) to hook block (3), and wind it in.
4. After winding in the wire rope, bring it in to wedge pocket (4) at
the side plate of the rear sheave block, and secure with the
wedge. (Extend the end of the wire rope approx. 10 cm more
than the wedge.) Check that the wire rope is fixed in position,
then fix the end of the wire rope with wire clip (5).
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PROCEDURE FOR REMOVAL AND INSTALLATION OF COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT SEGMENTS

1. Loosen set bolt (2), then remove lock bolt (3) and plate (6).
2. Loosen set bolt (5), then remove plate (4).
3. Using a crane, remove segment (1) from the frame.
REMARK
There are 3 segments each at the front and rear of the frame [1
segment: 1530 kg (3374 lb)]. If all 6 segments are removed, the
weight can be reduced by approx. 9180 kg (20242 lb).
INSTALLATION OF COUNTERWEIGHT SEGMENTS

WARNING
The weight of 1 segment is 1530 kg (3374 lb). If the mounting bolts are
loose, the segment will fall off, so be careful to tighten the bolts securely.
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1. Raise segment (1) with a crane and insert into the frame.
2. Insert plate (6) and tighten with lock bolt (3).
Tightening torque for lock bolt: Target at least 100 kg (221 lb)
3. Tighten plate (4) with set bolt (5).
4. Tighten lock bolt (3) and set bolt (5) again.
5. Tighten set bolt (2), then lock it with nut (7).
REMOVAL OF COUNTERWEIGHT
Stop the engine, then operate the counterweight lever 2 to 3 times
to the RETRACT and EXTEND positions to release the pressure
remaining in the cylinder piping circuit.
1. Remove counterweight (1).
2. Using a crane, remove frame (2).
Weight of frame: 2408 kg (5310 lb)
3. Using a crane, remove small link (3).
Weight of small link: 75 kg (165 lb)
4. Remove counterweight cylinder (4).
Weight of counterweight cylinder: 35 kg (77 lb)(each)
5. Using a crane, remove large link (3).
Weight of large link: 952 kg (2099 lb)
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INSTALLATION OF COUNTERWEIGHT
1. Install large link (5), small link (3), and counterweight cylinder
(4) to frame (2) to make the frame link assembly.
Be careful to install the front and rear cylinders in the correct
position and facing in the correct direction.
2. Using a crane, raise the frame link assembly and install it to the
gate frame in the following order.
(1) Install large link.
(2) Install small link.
(3) Using the crane, extend the frame so that the cylinder pin
can be inserted, and install the cylinder.
3. Connect the piping of cylinder (4).
4. Install counterweight segments (1).
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OPERATION COLD WEATHER OPERATION
COLD WEATHER OPERATION

PRECAUTIONS FOR LOW TEMPERATURE
If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.
FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see "USE OF
FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-8)".
COOLANT
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 amounts 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 or request a specialist company to carry out the operation. Antifreeze is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.
Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze.
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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 brand of antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-18)".
REMARK
If the machine is still in the same condition as when it was shipped from the factory, the cooling water will contain
Komatsu genuine Supercoolant (AF-NAC), so there is no need to change the coolant for temperatures down to -10
°C (14°F).
For temperatures below -10°C (14°F), adjust the density of the coolant. For details, see "CLEAN INSIDE OF
COOLING SYSTEM (PAGE 4-18)".
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COLD WEATHER OPERATION OPERATION
HEAT RETENTION DEVICE FOR ENGINE

The following heat-retention device is provided to allow normal operation of the engine.
RADIATOR SHUTTER
(if equipped)
Adjust the OPEN/CLOSE lever of the radiator shutter so that the indicator of the water temperature gauge is at the
position given below.
When using SAE30 engine oil

During operations, the indicator must be in the green range.
If the ambient temperature is above -10°C (14°F), set the
radiator shutter to the fully open position when carrying out
operations with loads.
In summer, set the radiator shutter to the fully open position
when carrying out operations, but the indicator of the engine
water temperature gauge should always be in the green range.
Never let it enter the red range.
BATTERY
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WARNING
The battery generates flammable gas. 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 the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger
that the battery may explode.
Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the
battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%. Insulate it against cold
temperature to ensure 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
20 0 -10 -20 -30
Charging (°C)
Rate (%)
100 1.28 1.29 1.30 1.31 1.32
90 1.26 1.27 1.28 1.29 1.30
80 1.24 1.25 1.26 1.27 1.28
75 1.23 1.24 1.25 1.26 1.27
REMARK
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the
electrolyte from freezing.
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OPERATION COLD WEATHER OPERATION
AFTER COMPLETION OF WORK

WARNING
Performing idle-running of the tracks is dangerous, so stay well away from the tracks.
To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the
following morning, 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 undercarriage.
As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine, store
the battery in a warm place, and install it the next morning.
AFTER COLD WEATHER

When the season changes and the weather becomes warmer, do as follows.
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 (PAGE 4-8)".
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If for any reason permanent antifreeze cannot be used, and an ethylene glycol base antifreeze (winter, one
season type) is used instead, or if no antifreeze is used, drain the cooling system completely. Thoroughly flush
out the cooling system and fill it with fresh coolant.
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LONG-TERM STORAGE OPERATION
LONG-TERM STORAGE
BEFORE STORAGE
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
separately.
If the ambient temperature is expected to drop below 0°C (32°F), always add antifreeze to the coolant.
Komatsu genuine Super Coolant (AF-NAC) is added to the cooling water, so there is no need to change the
density for temperatures down to -10°C (14°F).
If the temperature goes below -10°C (14°F), adjust the density. For details, see "CLEAN INSIDE OF COOLING
SYSTEM (PAGE 4-18)".
Turn the standing switch to the offside in position and set the fuel control lever to low idling.
Place the gear shift lever at the Neutral position, lock the gear shift lever with the parking lever. Do not lock the
brake pedal.
DURING STORAGE
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WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve
ventilation and prevent gas poisoning.
During the storage period, operate the machine once a month to prevent loss of the oil film at the lubricated parts.
At the same time, charge the battery.
When operating the counterweight, wipe off the grease coating the hydraulic cylinder rod.
AFTER STORAGE
NOTICE
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor
before using it.
When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease at all lubrication points.
When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after
starting the engine. If there is water in the oil, change all the oil.
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OPERATION TROUBLESHOOTING
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
When starting the engine after running out of fuel, fill the fuel tank with fuel, fill the fuel filter cartridge with fuel, then
hold the starting switch at the START position for 10 - 15 seconds, and start the engine.
METHOD OF TOWING MACHINE

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 level 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.
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TROUBLESHOOTING OPERATION
IF BATTERY IS DISCHARGED
WARNING
When checking or handling the battery, stop the engine and turn the
starting key to the OFF position before starting.
The battery generates hydrogen gas, so there is danger of explosion. Do
not bring lighted cigarettes near the battery or do anything that will
cause sparks.
Battery electrolyte is dilute sulphuric acid, and it will attack your clothes
and skin. If it gets on your clothes or on your skin, wash it immediately
off with large amounts of water. If it gets in your eyes, wash it out with
fresh water, and consult a doctor.
Wear protective glasses and rubber gloves when handling the battery.
When removing the battery, first disconnect the cable fro the ground
(normally, from the negative (-) terminal). When installing, install the
positive (+) terminal first. If a tool touches the cable connecting the
positive terminal and the chassis, there is danger that it will cause
sparks.
If the terminals are loose, there is danger that the defective contact may
generate sparks that will cause an explosion.
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When installing the terminals, install them tightly.
Check the positive (+) and negative (-) terminals carefully when
removing or installing.
REMOVAL AND INSTALLATION OF BATTERY

Before removing the battery, remove the ground cable (normally connected to the negative (-) terminal).
If any tool touches between the positive terminal and the chassis, there is a hazard of sparks being generated.
When installing the battery, connect the ground cable last.
When replacing the battery, secure it with battery fitting.
Tightening torque:Tightening battery terminal: 9.8 to 14.7 N·m (1 to 1.5 kgf·m, 7.2 to 10.8 lbft)
REMOVAL, INSTALLATION OF BATTERY CABLE

1. Remove battery cover (1).
2. Before removing the battery, remove the ground cable
(normally connected to the negative (-) terminal). If any tool
touches between the positive terminal and the chassis, there is
danger of sparks being generated. Loosen the nut of the
terminal and remove the wires from the battery.
3. When installing the battery, connect the ground cable last.
Insert the hole of the terminal on the battery and tighten the nut.
Tightening torque: 9.8 to 19.6 N·m (1 to 2 kgf·m, 7.2 to 14.5
lbft)
4. Install battery cover (1).
3 - 90
.
PRECAUTIONS WHEN CHARGING BATTERY

When charging the battery, if the battery is not handled correctly,
there is danger that the battery may explode. Always follow the
instructions in "IF BATTERY IS DISCHARGED (PAGE 3-90)" and
the instruction manual accompanying the charger, and do as
follows.
Set the voltage of the charger to match the voltage of the battery
to be charged. If the correct voltage is not selected, the charger
may overheat and cause an explosion.
Connect the positive (+) charger clip of the charger to the
positive (+) terminal of the battery, then connect the negative (-)
charger clip of the charger to the negative (-) terminal of the
battery. Be sure to fix the clips securely.
Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging, set
it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and
explode.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a danger that this will ignite the battery electrolyte and cause the battery to explode.
STARTING ENGINE WITH BOOSTER CABLE
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When starting the engine with a booster cable, do as follows.
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE
WARNING
When connecting the cables, never contact the positive (+) and negative
(-) terminals.
When starting the engine with a booster cable, 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 both machines to confirm that the work equipment lock levers (hook control, boom control, counterweight control),
parking lever, and brake lever are all in the LOCK position.
Check that each lever is in the NEUTRAL position.
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CONNECTING THE BOOSTER CABLES

Keep the starting switch of the normal machine and problem machine in the OFF position.
Connect the booster cable as follows, in the order of the numbers marked in the diagram.
1. Connect one clip (1) of booster cable (A) to the positive (+)
terminal of the discharged battery.
2. Connect the other clip (2) of booster cable (A) to the positive (+)
terminal of the booster battery.
3. Connect one clip of booster cable (B) to the negative (-)
terminal of the booster battery.
4. Connect the other clip of booster cable (B) to the engine block
of the problem machine.
STARTING THE ENGINE

1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the booster machine and keep it running at high idling speed.
3. Turn the starting switch of problem machine to the START position, and start the engine. If the engine doesn't
start at first, try it again after 2 minutes.
DISCONNECTING THE BOOSTER CABLES
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After the engine has started, disconnect booster cables in the reverse order in which they were connected.
1. Remove clip of booster cable (B) from the engine block of
problem machine.
2. Remove clip of booster cable (B) from negative (-) terminal of
the booster battery.
3. Remove clip of booster cable (A) from the positive (+) terminal
of booster battery.
4. Remove clip (4) of booster cable (A) from positive (+) terminal
of the discharged battery.
3 - 92
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OTHER TROUBLE
ELECTRICAL SYSTEM
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problem or causes which are not listed below, 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 speed disconnections)
Lamp flickers while engine is Fefective adjustment of alternator Adjust alternator belt tension
running belt tension For details, see EVERY 250
HOURS SERVICE
Abnormal noise is generated from Defective alternator ( Replace)
alternator
Starting motor does not crank Defective wiring ( Check, repair)
when ignition switch is turned ON Insufficient battery charge Charge
Pinion of starting motor keeps Insufficient battery charge Charge
going in and out
Starting motor turns engine Insufficient battery charge Charge
sluggishly Defective starting motor ( Replace)
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Starting motor disengages before Defective wiring ( Check, repair)
engine starts Insufficient battery charge Charge
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CHASSIS

Oil pressure in torque converter Improper tightening of oil pipe, Check, repair
fails to rise pipe joint, air leaking in or oil
leaking out because of damage
Wear, scuffing of gear pump ( Check, replace)
Insufficient oil in transmission Add oil to the specified level. For
case details, see CHECK BEFORE
STARTING
Clogged oil filter element strainer Clean. For details, see EVERY
in transmission case 500 HOURS SERVICE
Torque converter is overheats Clogged radiator Clean, wash radiator core
Loose fan belt Replace fan belt
Engine water temperature is high See Engine related parts
Clogged oil cooler ( Clean or replace)
Oil pressure too low Go to "Oil pressure in torque
converter fails to rise"
Lack of flow of lubricant caused ( Replace gear pump)
by wear of power train gear pump
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Lacks drawbar pull (machine does Lack of engine horsepower See Engine related parts
not pick up speed) Oil pressure in torque converter Go to "Oil pressure in torque
is too low converter fails to rise"
Steering clutch is slipping ( Check, repair)
Machine will not move off when Lack of oil in steering clutch case Add oil to the specified level.
gear shift lever is placed at For details, see CHECK
FORWARD BEFORE
Transmission oil pressure does Go to oil pressure in torque
not rise converter fails to rise
Steering clutch slips
Wear, scuffing of gear pump ( Check, repair)
Clogged oil strainer element in Clean. For details, see EVERY
steering clutch case 1000 HOURS SERVICE
Defective gear shift lever and Check, wiring
steering lever
Parking lever is at LOCK Brake lock lever is at FREE
position position
Does not steer even when steering Brake is not applied on side ( Adjust linkage,
is operated which is pulled Check brake pressure)
Defective gear shift lever and ( Check, wiring)
steering lever
Machine doesn't stop when brake Defective brake adjustment ( Adjust linkage,
pedal are depressed Check brake pressure)
Defective Brake pedal ( Check, wiring)
Track comes off Track is too loose Adjust track tension. For details,
see WHEN REQUIRED.
Sprocket develops abnormal wear Track is too loose or too tight Adjust track tension. For details,
see WHEN REQUIRED.
Lack of power, speed when Lack of hydraulic oil Add oil to the specified level
retracting counterweight Clogged cartridge Replace
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Defective hook RAISE, LOWER Lack of hydraulic oil Add oil to the specified level
Defective boom RAISE, LOWER Oil leaking from piping Check, repair
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ENGINE

Engine oil pressure gauge flashes Engine oil pan oil level is low Add oil to specified level, see
when engine speed is raised after (sucking in air) CHECK BEFORE STARTING
completion of warm-up Clogged oil filter cartridge Replace cartridge, see EVERY
Engine oil pressure gauge is in red 250 HOURS SERVICE
range Defective tightening of oil pipe ( Check, repair)
joint, oil leakage from damaged
part
Steam is emitted from top part of Cooling water level low, water Add cooling water, repair, see
radiator (pressure valve) leakage CHECK BEFORE STARTING
Loose fan belt Replace fan belt
Dirt or scale accumulated in Change cooling water, clean
cooling system inside of cooling system, see
WHEN REQUIRED
Engine water temperature monitor Clogged radiator fin or damaged Clean or repair, see WHEN
flashes fin REQUIRED
Engine water temperature gauge is Defective thermostat ( Replace thermostat)
Loose radiator filler cap (high Tighten cap or replace packing
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in red range
altitude operation)
Engine does not start when starting Lack of fuel Add fuel, see CHECK BEFORE
motor is turned STARTING
Air in fuel system Repair place where air is sucked
in
Defective fuel injection pump or ( Replace pump or nozzle)
nozzle
Starting motor cranks engine See ELECTRICAL SYSTEM
sluggishly
Defective valve clearance ( Adjust valve clearance)
Exhaust gas is white or blue Too much oil in oil pan Add oil to specified level, see
Improper fuel Change to specified fuel
Exhaust gas occasionally turns Clogged air cleaner element Clean or replace, see WHEN
black REQUIRED
Defective nozzle ( Replace nozzle)
Defective compression ( Adjust valve clearance)
Defective turbocharger ( Clean or replace, turbocharger)
Combustion noise occasionally Defective nozzle ( Replace nozzle)
makes breathing sound
Abnormal noise generated Low grade fuel being used Change to specified fuel
(combustion or mechanical) Overheating See item "Engine water
temperature monitor flashes".
Damage inside muffler ( Replace muffler)
Excessive valve clearance ( Adjust valve clearance)
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4-1
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GUIDES TO MAINTENANCE MAINTENANCE
GUIDES TO MAINTENANCE
Do not perform any inspection and maintenance operation that is not found in this manual.
Stop the machine on flat hard ground when performing inspections and maintenance.
CHECK SERVICE METER:

Check the service meter reading every day to see if the time has come for any necessary maintenance to be
performed.
KOMATSU GENUINE REPLACEMENT PARTS:

Use Komatsu genuine parts specified in the Parts Book as replacement parts.
KOMATSU GENUINE OILS:

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient
temperature.
ALWAYS USE CLEAN WASHER FLUID:

Use automobile window washer fluid, and be careful not to let any dirt get into it.
CLEAN OIL AND GREASE:

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

Wash the machine to keep it clean and make it easy to see problem parts. In particular, keep the area around the
grease fittings, breathers, and oil level gauges (oil inspection window) clean to avoid the entry of dirt.
BE CAREFUL OF HOT WATER AND OIL:

It is dangerous to drain oil or water or to replace the filters immediately after stopping. Wait for the temperature to
go down before starting. However, if the oil is cold, warm the oil up to a suitable temperature [20 - 40°C (68 - 104
°F)] before draining it.
CHECK FOREIGN MATERIAL IN DRAINED OIL:

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:
If your machine is equipped with a fuel strainer, do not remove it while fueling.
OIL CHANGE:
When checking or changing the oil, carry out the operation in a place that is free of dust to prevent the entry of dirt.
WARNING TAG:
When draining the oil or coolant, hang warning signs in the operator's compartment to prevent any other person from
starting the engine by mistake.
OBEY PRECAUTIONS:
Always follow the caution signs stuck to the machine when carrying out operations.
4-2
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MAINTENANCE GUIDES TO MAINTENANCE
WELDING INSTRUCTIONS:
Turn off the engine starting switch.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3.3 ft) of the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happens to come between the part being welded 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.
FIRE PREVENTION:
When washing parts, use a non-flammable detergent or diesel oil. When using diesel oil, keep away from flame or
fire.
CLAMP FACES:
When removing parts where there are O-rings or gasket seals fitted, clean the mounting surface and replace with
new parts.
When doing this, do not forget to assemble the O-ring or gasket.
OBJECTS IN YOUR POCKETS:

When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
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nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or 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.
CLEANING MACHINE:
Do not direct any high-pressure jet directly at the radiator when washing the machine.
Be careful not to get water on electrical components.
PRE- AND POST-WORK CHECKS:

When carrying out operations in muddy water, in rain, on beaches, or in snow, check that all plugs and valves are
properly tightened before starting operations. After finishing operations, wash the machine and check all parts for
cracks, damage, loose nuts and bolts, and for missing parts. Carry out greasing as soon as possible.
In particular, grease all work equipment pins that have entered muddy water.
DUSTY WORKSITES:
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:

If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade
of oil. Never mix different brand or grade of oil.
4-3
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OUTLINES OF SERVICE MAINTENANCE
OUTLINES OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual.
Even if the oil is not dirty, always 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 the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For
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those who wish to use this service, please contact your Komatsu distributor.
FUEL
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C (5
°F)). 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
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 filled with the antifreeze recommended by Komatsu when the machine is shipped from
the factory.
This antifreeze is effective in preventing corrosion of parts in the cooling system.
Change the antifreeze periodically. For details, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-18)".
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 (PAGE 4-18)".
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 due to air entering
the coolant.
4-4
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MAINTENANCE OUTLINES OF SERVICE
GREASE
Grease is used to prevent seizure and noises 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)

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 ITEMS

Analysis of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
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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
Sampling interval
250 hours: Engine
500 hours: Other components
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Perform sampling at regular fixed intervals.
Do not perform 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.
4-5
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OUTLINES OF SERVICE MAINTENANCE
STORING OIL AND FUEL

Keep indoors to prevent any water, dirt, or other impurities from getting in.
When keeping drum cans for a long period, put the drum on its side so that the filler port of the drums is at the side
to prevent moisture from being sucked in.
If drums 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
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,
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
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It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This
will cause an electrical short circuit and may lead to malfunction of the machine. Do not wash the inside of the
operator's cab with water. When washing the machine, be careful not to let water get into the electrical
components.
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and
checking battery fluid level.
Never remove or disassemble any components (electrical components) installed to the machine.
Never install any electric components other than those specified by Komatsu.
External electro-magnetic interference may cause malfunction of the control system controller, so before
installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
When working at the seashore, carefully clean the electric system to prevent corrosion.
When installing an operator's cab cooler or any other electrical equipment, connect it to an independent power
source connector. The cables to supply power to the optional equipment must never be connected to the fuse,
starting switch, or battery relay.
4-6
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MAINTENANCE WEAR PARTS LIST
WEAR PARTS LIST

Replace filter elements and other wear parts and period maintenance or before they reached the wear limit.
Replace wear parts properly to enable this machine to be used more economically. When replacing parts, always
use high-quality Komatsu genuine parts. The parts differ according to the machine serial number, so when ordering
parts, always inform your Komatsu distributor of the machine serial number.
WEAR PARTS LIST

The parts in parentheses are to be replaced at the same time.
Replacement
Item Part No. Part Name Weight Q'ty
frequency
Engine oil filter 600-211-1231 Cartridge - 1
175-49-11580 Element 1
Transmission filter -
(07000-02115) (O-ring) (1)
Every 250 hours
Steering filter 175-49-11580 Element 2 service
-
(07000-03120) (O-ring) (2)
Winch oil filter 144-60-11160 Element 1
-
(07000-12115) (O-ring) (1)
7.3 m (23 ft 11 in) 167 kg 95 m
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176-76-12161 wire rope (368 lb) (31 ft 2 in)
Wire rope for hook -
(196-76-12111) [8.5 m (27 ft 11 in) [184 kg [105 m
wire rope] (406 lb)] (34 ft 5 in)]
7.3 m (23 ft 11 in)
wire rope 114 kg 65 m
Wire rope for boom 176-76-12171 -
[8.5 m (27 ft 11 in) (251 lb) (21 ft 4 in)
wire rope]
Every 500 hours
Fuel filter 600-311-7132 Cartridge - 1
service
Every 1000 hours
Corrosion resistor 600-411-1151 Cartridge - 1
service
130-60-48210 Element 1 Every 2000 hours
Counterweight filter -
(07000-03078) (O-ring) (1) service
6128-81-7043 Element Ass'y - 1
Air cleaner -
600-181-4401 Outer element Ass'y - 1
NOTICE
When handling parts that weigh more than 25 kg (55 lb), remember that they are heavy objects, and take the necessary care.
4-7
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USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO

AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
Use the oil recommended according to the ambient temperature in the chart below.
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity means
the amount of oil needed to refill the system during inspection and maintenance.
When starting the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil of
SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C (50°F) more
or less during the day.
The specified brands for hydraulic oil MIL-H-5606C are as shown in the table below.
Manufacturer Brand
COSMO OIL COSMO Hydro HV15K
MOBIL Aero HFA, Mobil Hydro Fluid H0-15
MOBIL OIL
(EJ60/196), Mobil Aero HFD
SHOWA SHELL OIL SPECIAL Aero Shell Fluid 41, Fluid Special
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FUJI KOSAN Moebius HF15
IDEMITSU KOSAN Daphnie Hydraulic Fluid 243
4-8
.
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
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* For details of MIL-H-5606C, see the previous page, and use the oil recommended by Komatsu.
For details of the procedure for changing the oil, see "OIL (PAGE 4-4)".
NOTICE
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel
consumption and good exhaust gas characteristics. For this reason, it requires high precision for the parts and good lubrication.
If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability.
4-9
.
Steering clutch case

Final drive
Engine (incl. transmission, Winch Counterweight Fuel Cooling
case
oil pan torque converter and case tank tank system
(each)
bevel gear casses)
Specified Liters 42 230 68 125 47 640 145

amount US gal 11.1 60.77 17.97 33.03 12.42 169.09 38.31
Refil Liters 37 190 68 100 29 - -

capacity US gal 9.78 50.20 17.97 26.42 7.66 - -
REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulfur content is above 0.5%.
When starting the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil
of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C (50°
F) more or less during the day.
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Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval 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
Fuel sulfur content Engine oil change interval

0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
4 - 10
.
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. 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.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, 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
*RPM delo 400 Universal thuban Marfak all purpose 2
6 CALTEX AF engine coolant
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RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -
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
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*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
.
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. 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
*Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease
PETROFIN FINA potonic N
15 FINA kappa TD FINA marson EPL2 FINA tamidor
A FINA potonic NE
Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty
Sunoco ultra prestige Sunoco antifreeze
Sunoco GL5
17 SUN - 2EP and summer
gear oil
Sun prestige 742 coolant
*Ursa super plus Multifak EP2 Coda 2055 startex
18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
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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

TORQUE LIST
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.
Thread Width Tightening torque

diameter across
Target value Service limit
of bolt flats
(a)(mm) (b)(mm) N·m kgf·m lbft N·m kgf·m lbft
6 10 13.2 1.35 9.8 11.8-14.7 1.2-1.5 8.7-10.8

8 13 31 3.2 23.1 27-34 2.8-3.5 20.3-25.3
10 17 66 6.7 48.5 59-74 6.0-7.5 43.4-54.2
12 19 113 11.5 83.2 98-123 10.0-12.5 72.3-90.4
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14 22 177 18 130.2 157-196 16.0-20.0 115.7-144.7
16 24 279 28.5 206.1 245-309 25.0-31.5 180.8-227.8

18 27 382 39 282.1 343-425 35.0-43.5 253.2-314.6
20 30 549 56 405.0 490-608 50.0-62.0 361.7-448.4
22 32 745 76 549.7 662-829 67.5-84.5 488.2-611.2
24 36 927 94.5 683.5 824-1030 84.0-105.0 607.6-759.5
27 41 1320 135.0 976.5 1180-1470 120.0-150.0 868.0-1085.0

30 46 1720 175.0 1265.8 1520-1910 155.0-195.0 1121.1-1410.4
33 50 2210 225.0 1627.4 1960-2450 200.0-250.0 1446.6-1808.3
36 55 2750 280.0 2025.2 2450-3040 250.0-310.0 1808.3-2242.2
39 60 3280 335.0 2423.1 2890-3630 295.0-370.0 2133.7-2676.2
Apply the following table for Hydraulic Hose.

Thread Width Tightening torque
diameter across
Target value Permissible range
flats
a (mm) b (mm) N·m kgf·m lbft N·m kgf·m lbft
10 14 14.7 1.5 10.8 12.7 - 16.7 1.3 - 1.7 9.4 - 12.3
14 19 29.4 3.0 21.7 27.5 - 39.2 2.8 - 4.0 20.3 - 28.9
18 24 78.5 8.0 57.9 58.8 - 98.1 6.0 - 10.0 43.4 - 72.3

22 27 117.7 12.0 86.6 88.3 - 137.3 9.0 - 14.0 65.1 - 101.3
24 32 147.1 15.0 108.5 117.7 - 176.5 12.0 - 18.0 86.8 - 130.2
30 36 215.7 22.0 159.1 176.5 - 245.2 18.0 - 25.0 130.2 - 180.8
33 41 255.0 26.0 188.1 215.7 - 284.4 22.0 - 29.0 159.1 - 209.8
4 - 13
.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

For using the machine safely for an extended period if time, you are required 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 important 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 periodic
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 perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose
clamps and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the critical parts.
SAFETY CRITICAL PARTS

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.
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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 for the latest part number when ordering parts.
No. Safety critical parts for periodic replacement Q'ty Replacement interval
1 Fuel hose (fuel tank - injection pump) 1
2 Fuel return hose (injection pump - fuel tank) 1
3 Fuel return hose (injection nozzle - fuel tank) 2
4 Transmission filter outlet hose 1
5 Hose (power train pump - power train filter) 1
Every 2 years or
6 Steering clutch case filter outlet hose 1 4000 hours,
7 Hose (steering pump - filter outlet) 1 whichever comes
sooner
8 Hose (transmission valve - transmission oil cooler) 1
9 Hose (transmission oil cooler - transmission case) 1
10 Turbocharger lubricating hose 1
11 Fuel hose (feed pump - fuel filter) 1
12 Fuel hose (fuel filter - injection pump) 1
13 Seat belt 1 Every 3 years
4 - 14
.
MAINTENANCE MAINTENANCE SCHEDULE CHART
MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
Change oil in engine oil pan, replace engine oil filter cartridge 4- 40
Replace transmission filter element and steering clutch case filter element 4- 43
Change oil in steering clutch case (including transmission case, torque converter case), clean strainer 4- 47
Change oil in final drive case 4- 49
Change oil in winch case, clean strainer 4- 50
Change oil in counterweight tank, replace filter element 4- 59
WHEN REQUIRED
Clean inside of cooling system 4- 18
Check, clean and replace air cleaner element 4- 21
Check track tension 4- 23
Check and tighten track shoe bolts 4- 25
Check electrical intake air heater 4- 25
Adjust idler clearance 4- 25
Clean, check radiator fins 4- 26
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Clean fuel tank strainer 4- 26
Drain water and sediment in fuel tank 4- 26
Replace alternator drive belt 4- 27
Check undercarriage oil 4- 28
Clean air conditioner air filter (fresh/recirc filter) 4- 29
Check air conditioner refrigerant gas level 4- 29
Lubricate door hinge 4- 30
Check door latch 4- 30
Replace wiper blade 4- 31
Bleeding air in hydraulic system 4- 32
Lubricating 4- 32
4 - 15
.
MAINTENANCE SCHEDULE CHART MAINTENANCE
EVERY 250 HOURS SERVICE

Lubricating 4- 34
Check alternator drive belt tension, adjust 4- 35
Check level of battery electrolyte 4- 36
Check brake performance 4- 39
Change oil in engine oil pan, replace engine oil filter cartridge 4- 40
Check oil level in final drive case, add oil 4- 42
Check oil level in counterweight tank, add oil 4- 42
Replace transmission filter element 4- 43
Replace steering clutch case filter element 4- 44

Replace fuel filter cartridge 4- 45
Clean final drive case breather 4- 46
Clean steering clutch case breather 4- 46
Clean winch case breather 4- 46
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Change oil in steering clutch case (including transmission case, torque converter case), clean strainer 4- 47
Change oil in final drive case 4- 49
Change oil in winch case, clean strainer 4- 50
Check, clean fuel strainer 4- 52
Check oil in undercarriage parts 4- 52
Check oil level in recoil spring case, add oil 4- 53
Check, clean radiator fin 4- 53
Lubricating 4- 54
Replace corrosion resistor cartridge 4- 55
Check tightening parts of turbocharger 4- 55

Lubricating 4- 56
Change oil in counterweight tank, replace filter element 4- 59
Clean engine breather element 4- 61
Clean and check tutbocharger 4- 61
Check play of turbocharger rotor 4- 61
Check alternator, starting motor 4- 61
Check engine valve clearance, adjust 4- 61

Check water pump 4- 62
Check vibration damper 4- 62
Check fan pulley and tension pulley 4- 62
4 - 16
.
MAINTENANCE SERVICE PROCEDURE
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
Perform the following maintenance only after the first 250 hours.
Change oil in engine oil pan, replace engine full-flow filter cartridge
Replace transmission filter element and steering clutch case filter element
Change oil in steering clutch case (including transmission case, torque converter case), clean strainer
Change oil in final drive case
Change oil in winch case, replace filter element
Change oil in counterweight tank, replace filter element
For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS, 1000 HOURS and
2000 HOURS SERVICE.
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4 - 17
.
SERVICE PROCEDURE MAINTENANCE
WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM
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.
The inside of the cooling system is cleaned with the engine running. When standing up from the operator's seat or leaving the
machine, set the parking lever, brake lock lever, and work equipment lock levers (hook control, boom control, counterweight
control) to the LOCK position.
For details when starting the engine, see "CHECK BEFORE STARTING ENGINE, ADJUST (PAGE 3-38)" and "STARTING ENGINE
(NORMAL, IN COLD WEATHER) (PAGE 3-55)" 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.
Flushing inside of cooling system,

Type of antifreeze Replacing corrosion resistor
changing antifreeze
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Komatsu genuine Super Coolant
Every 2 years or every 4000 hours,
AF-NAC (anti-corrosion all-season - (See REMARK below)
whichever comes sooner
type)
Every 1000 hours and when
Every 1 year or every 2000 hours,
AF-NAL antifreeze (all-season type) flushing inside of cooling system or
whichever comes sooner
changing antifreeze
When using only corrosion resistor Every 6 months or every 1000 Every 1000 hours and when
and not using antifreeze hours, whichever comes sooner flushing inside of cooling system
REMARK
Komatsu genuine Super Coolant (AF-NAC) has both antifreeze effect and anti-corrosion effect, so there is no
need to use a corrosion resistor. Replace with the corrosion resistor cover. For details of the corrosion resistor
cover, please contact your Komatsu distributor.
When continuing to use the corrosion resistor cartridge, it cannot stand being left as it is for a long period, so
replace it with a new cartridge every time the antifreeze is changed.
Each brand of antifreeze uses a different combination of additives, so do not mix brands.
4 - 18
.
Stop the machine on level ground when cleaning or changing the coolant.
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 mixing
rate table given below.
It is actually better to estimate a temperature about 10°C (18°F) lower when deciding the mixing rate.
Mixing rate of water and antifreeze
Min. atmospheric °C - 10 - 15 - 20 - 25 - 30 - 35 - 40
temperature °F 14 5 -4 - 13 - 22 - 31 - 40
liters 43.5 52.0 59.5 67.0 72.5 78.5 84.0
Amount of antifreeze
US gal 11.49 13.74 15.72 17.70 19.16 20.74 22.19
liters 101.5 93.0 85.5 78.0 72.5 66.5 61.0
Amount of water
US gal 26.82 24.57 22.59 20.61 19.15 17.57 16.12
Volume ratio % 30 36 41 46 50 54 58
WARNING
Antifreeze is flammable, so keep it away from flame.
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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.
4 - 19
.
1. Stop the engine and close the valve (1) of corrosion resistor
cartridge.
2. Turn radiator cap (2) slowly to remove it.
3. Set a container to catch the coolant, open drain valve (3) at the
bottom of the radiator and drain valve (4) at the bottom of oil
cooler and drain off the coolant.
4. After draining the antifreeze solution, close drain valves (3) and
(4), then fill with clean water. After the radiator is filled with
water, start and run the engine at low idling speed. After the
water temperature rises above 90 °C (194 °F), run the engine
for about 10 minutes.
5. Stop the engine and open drain valves (3) and (4) to drain the
water.
6. After draining the water, clean the cooling system with cleaning
agent.
For the cleaning method, see the instructions for the cleaning
agent.
7. Close drain valves (3) and (4).
8. Replace the corrosion resistor, and open valve (1).
For details on the corrosion resistor replacement method, see
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"EVERY 1000 HOURS SERVICE (PAGE 4-47)".
9. Add coolant mixed with antifreeze until it overflows from the
water filler.
Decide the proportions of antifreeze and water according to the
table for the mixing rate of water and antifreeze.
10. To remove the air contained in the coolant, run the engine at
low idle for 5 minutes, then run for a another 5 minutes at high
idle. (When doing this, leave radiator cap (2) OFF.)
11. Stop the engine, wait for approx. 3 minutes, then add coolant
until the coolant level is near the coolant filler port, and tighten
the cap. Check the coolant level and add coolant if necessary.
4 - 20
.
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
WARNING
When using compressed air and, there is danger that dirt may fly and cause personal injury.
Always wear protective glasses, thick gloves, anti-dust mask, and other protective clothing.
CHECKING
If air cleaner clogging caution lamp (1) lights up, clean the outer
element of the air cleaner.
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CLEANING OR REPLACING OUTER ELEMENT
NOTICE
Never remove the inner element. It will allow dirt to enter and cause
failure of the engine.
Do not use a screwdriver or any other tool.
1. Remove wing nut (2), then remove cover (3) and take out the
outer element.
2. Clean the inside of the body and the dust cup.
4 - 21
.
3. 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) Remove one seal from the element whenever the element
has been cleaned.
2) Replace the outer element if it has been cleaned 6 times
repeatedly or used throughout a year. Replace the inner
element at the same time.
3) Replace both inner and outer elements when the air
cleaner clogging senser shows abnormalities immediately
after installing the cleaned outer element even though it
has not been cleaned 6 times.
4) Check inner element mounting nuts for looseness and, if
necessary, retighten.
5) Replace seal washer (4) or wing nut (2) with new parts if
they are broken.
6) Remove evacuator valve (5) and clean it with compressed
air. After cleaning, install it again.
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NOTICE
If small holes or thinner parts are found on the element when it is checked
with an electric bulb after cleaning and drying, replace the element.
Do not use an element whose folds or gasket or seal are damaged.
When cleaning the element, do not hit it or beat it against something.
4. Set the cleaned element.
REPLACING INNER ELEMENT

1. Remove the outer element and the cover, 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 and tighten it with nuts.
Do not clean and reinstall a inner element.
5. Install the outer element and the cover.
4 - 22
.
CHECK TRACK TENSION

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
Stop the machine on level ground (stop with the transmission in
FORWARD without applying the brake). Then place a straight bar
on the track shoes between the carrier roller and the idler as shown
in the figure, and measure the clearance between the bar and the
grouser at the midpoint. If the clearance (A) is 20 to 30 mm (0.79
to 1.18 in), the tension is standard.
If the track tension is not at the standard value, adjust it in the
following manner.
ADJUSTMENT
WARNING
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Grease inside the adjusting mechanism is under high pressure.
Grease coming from lubricator (2) under pressure can penetrate the body
causing injury or death. For this reason, do not loosen lubricator (2) more
than one turn. Do not loosen any part other than lubricator (2).
Furthermore, do not bring your face in front of grease fitting (1).
If track tension is not relieved by this procedure, contact your Komatsu
distributor for repairs.
WHEN INCREASING TENSION

1. Open cover (3).
NOTICE
There is a safety label stuck to the back of cover (3). Be careful not to damage the safety label.
2. Pump in grease through the grease fitting (1) with a grease pump.
3. To check that the correct tension has been achieved, move the machine backwards and forwards.
4. Check the track tension again, and if the tension is not correct, adjust it again.
5. Continue to pump in grease until S becomes 0 mm (0 in). If the
tension is still loose, the pin and bushing are excessively worn,
so they must be either turned or replaced. Please contact your
4 - 23
.
WHEN LOOSENING TENSION
WARNING
It is extremely dangerous to release the grease by any method except the procedure given below.
If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs.
1. Open cover (3).
NOTICE
There is a safety label stuck to the back of cover (3). Be careful not to damage the safety label.
2. Loosen lubricator (2) gradually to release the grease.

3. Turn lubricator (2) a maximum of one turn.
4. If the grease does not come out smoothly, move the machine
backwards and forwards a short distance.
5. Tighten lubricator (2).
6. To check that the correct tension has been achieved, move the
machine backwards and forwards.
7. Check the track tension again, and if the tension is not correct,
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adjust it again.
WHEN REMOVING TRACK
WARNING
Depending on the situation, the operation to remove the track may be extremely dangerous.
Before removing the track, if the procedure "WHEN LOOSENING TENSION (PAGE 4-24)" does not loosen the track tension, contact
your Komatsu distributor for repairs.
4 - 24
.
CHECK AND TIGHTEN TRACK SHOE BOLTS

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

1. First tighten to a tightening torque of 784 ± 78.4 N·m (80 ± 8 kgf·m, 578.6 ± 57.9 lbft)) then check that the nut
and shoe are in close contact with the link contact surface.
2. After checking, tighten a further 120° ± 10°.
ORDER FOR TIGHTENING

Tighten the bolts in the order shown in the diagram on the right.
CHECK ELECTRICAL INTAKE AIR HEATER
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(Starting aid)
Before starting the cold season (once a year) please contact your Komatsu distributor to have the electrical heater
for the engine checked for dirt or disconnections.
ADJUST IDLER CLEARANCE

The idler moves forward and backward under external pressure
when this happens, side guide (1) and guide plate (2) become
worn.
As they become worn, there is side play in the idler, or the idler
turns at an angle, causing the track to come off or resulting in
uneven wear, so adjust as follows.
ADJUSTMENT
1. Drive the machine for 8 to 12 m (24.4 to 36.6 ft) on flat ground,
then measure clearance A (4 places: left, right, inside outside)
between the track frame and side guide (1).
2. If clearance A is more than 3 mm (0.1 in), remove bolt (3), then
take out shim (4), and adjust to that the clearance on one side
is less than 0.5 mm (0.02 in).
REMARK
There are two types of shim (thickness: 0.5 mm (0.02 in) and 1.0
mm (0.04 in).
4 - 25
.
CLEAN, CHECK RADIATOR FINS
WARNING
For the cleaning and check, stop the engine without fail and confirm that the fan is not rotating, and carry out the work.
When the radiator fins are blocked with mud, dirt, or debris, clean as follows.
1. Loosen bolts (1) and open radiator grille (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.
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REMARK
Check the hydraulic cooler hoses. If any hose is cracked or hardened by age, replace with a new hose. Also check
and tighten all loose hose clamps.
CLEAN FUEL TANK STRAINER

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.
DRAIN WATER AND SEDIMENT IN FUEL TANK

Carry out this procedure after the machine has been at rest for a
long time and after a long spell of rainy days.
Loosen valve (1) at the bottom of the tank and drain sediment
accumulated on the bottom together with mixed water and fuel.
4 - 26
.
REPLACE ALTERNATOR DRIVE BELT
CHECK, REPLACE ALTERNATOR BELT

1. Loosen 2 cover mounting bolts (6) and remove the cover.
2. Loosen nuts (1), (2), and (5) and the bolts, then turn nut (4) and
adjust the belt tension.
3. After adjusting, tighten the bolts and nuts (1), (2), and (5) to
secure alternator (3) in position.
4. Fit the cover and tighten with mounting bolts (6).
Check that the cover does not contact the rotating portion of
the alternator.
5. Check each pulley for breakage, wear of the V-groove, and wear of the V-belt. In particular, check that the V-belt
does not contact the bottom of the V-groove.
6. If there is no more allowance to adjust the elongation of the belt, or the V-belt is cut or cracked, replace the
V-belt.
7. After replacing the belt, operate for one hour, then adjust again.
Push a point midway between the alternator pulley and the drive
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pulley with your thumb. The deflection and pushing force should
be as follows.
When replacing with new belt: 13 to 16 mm (0.5 to 0.6 in)[approx.
10 kg (98.1 N)]
CHECK, REPLACE AIR CONDITIONER BELT

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 bolt (1) to apply tension to the V-belt.
To check the belt tension, push a point midway between the air
compressor pulley and fan pulley with your thumb. The
deflection should be approx. 10 mm (0.4 in) with a finger force
of approx. 6 kg (58.8 N).
4 - 27
.
CHECK UNDERCARRIAGE OIL

Stop the machine on level ground, and check for any reduction in
the oil at the idler (portion P), track roller (portion Q), and carrier
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 is removed, the oil level
is low. Contact your Komatsu distributor for repairs.
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4 - 28
.
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)

Clean the air conditioner air filter if it becomes clogged or if there is
dirt or oil stuck to it.
1. Open the inspection cover (1).
2. Loosen nuts (2) and take out air filter (3).
3. Clean filter (3) with compressed air. If there is oil on the filter,
or if the filter is extremely dirty, rinse the filter in a neutral
detergent. After rinsing, dry completely and install again.
REMARK
If the filters cannot be cleaned with air or in water, replace them
with new ones.
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CHECK AIR CONDITIONER REFRIGERANT GAS LEVEL
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 refrigerant level is low, the cooling effect will drop. Run the
engine at full speed and the cooler at high speed, and check the
condition of the refrigerant by watching the flow in the refrigerant
circuit through the sight glass (inspection window) of the receiver.
Open cover (1) on the roof outside the cab. The receiver is inside.
No bubbles in refrigerant flow: Suitable
Some bubbles in flow
(bubbles pass continuously): Lack of refrigerant
Colorless, transparent: No refrigerant
REMARK
When there are bubbles, the refrigerant gas level is low, so contact your refrigerant dealer to have refrigerant
added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
New Freon R134a is used as the refrigerant.
Charge amount of air conditioner refrigerant (gas): 1100 g
4 - 29
.
LUBRICATE DOOR HINGE

If the door makes a squeaking noise when it is opened or closed,
spray lubricant in through the split in the hinge bushing.
If the bushing is worn, replace the hinge.
CHECK DOOR LATCH
WARNING
It is dangerous if the door moves unexpectedly during the check.
Stop the engine and set the brake lock lever securely to the LOCK position.
Check
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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 portion (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.
4 - 30
.
REPLACE WIPER BLADE

If the blade is damaged, it will not wipe the window clean, so
replace the blade.
REPLACEMENT
FRONT, REAR WIPER

1. Remove screw (1), then remove the blade.
2. Install a new blade, then tighten screw (1) securely.
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REAR WIPER
1. Remove E-ring (1).
The blade can then be removed.
2. Install a new blade, then install securely with E-ring (1).
DOOR WIPER
1. The wiper blade is hooked at portion A, and it can be easily
removed.
2. Install the new blade and hook it securely.
4 - 31
.
BLEEDING AIR IN HYDRAULIC SYSTEM

For details, see "OPERATIONS AND CHECKS AFTER STARTING ENGINE (NORMAL, IN COLD WEATHER)
(PAGE 3-58)".
It is necessary to start the engine and operate the counterweight, so see the OPERATION Section for details.
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 counterweight cylinder
1) Run the engine at low idling, and extend and retract the cylinder 4 to 5 times to a point approx. 100 mm (4
in) before the end of the stroke. Be careful not to operate the cylinder to the end of its stroke.
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.
LUBRICATING
1. Universal joint for winch
(2 places)
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4 - 32
.

For the following items, see "CHECK BEFORE STARTING (PAGE 3-40)".
Check coolant level, add coolant
Check fuel level, add fuel
Check oil level in engine oil pan, add oil
Check oil level in steering clutch case (including transmission, torque converter case), add oil.
Check brake pedal travel
Check oil level in counterweight tank, add oil
Check oil level in winch case, add oil
Check electric wiring
Check that lamps light up
Check horn sound
Check, inspect moment indicator (when equipped with standard boom)
Lubricating
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4 - 33
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LUBRICATING
1. Extend the counterweight fully, set the boom parallel to the ground surface, 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) Fan pulley (1 place)
(2) Tension pulley (1 place)
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4 - 34
.
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST
CHECKING
Push a point midway between the alternator pulley and the drive
pulley with your thumb. The deflection and pushing force should
be as follows.
When replacing with new belt: 13 to 16 mm (0.5 to 0.6 in)[approx.
10 kg (98.1 N)]
ADJUSTING
1. Loosen 2 cover mounting bolts (6) and remove the cover.
2. Loosen nuts (1), (2), and (5) and the bolts, then turn nut (4) and
adjust the belt tension.
3. After adjusting, tighten the bolts and nuts (1), (2), and (5) to
secure alternator (3) in position.
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4. Fit the cover and tighten with mounting bolts (6).
Check that the cover does not contact the rotating portion of
the alternator.
5. Check each pulley for breakage, wear of the V-groove, and wear of the V-belt. In particular, check that the V-belt
does not contact the bottom of the V-groove.
6. If there is no more allowance to adjust the elongation of the belt, or the V-belt is cut or cracked, replace the
V-belt.
7. After replacing the belt, operate for one hour, then adjust again.
4 - 35
.
CHECK LEVEL OF BATTERY ELECTROLYTE

Perform 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 accelerate deterioration of the
inside of the battery and reduce the service life of the battery. In addition, it may 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 cover (1) at the rear right side of the machine. The batteries
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are installed at (A) part.
4 - 36
.
WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY

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.
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
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baking soda (sodium bicarbonate), then flush it away with a large
amount of water or consult your Komatsu distributor or battery
maker.
4 - 37
.
WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY

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.
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2. After adding distilled water, tighten cap (1) 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.
WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL

If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
4 - 38
.
CHECK BRAKE PERFORMANCE
WARNING
If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately.
Before starting the engine, check that the area around the machine is safe, then do as follows.
1. Start the engine.
2. Set parking lever (1) to the FREE position.
Leave the parking lever at the FREE position.
3. Set brake lock lever (2) to the FREE position.
4. Depress brake level (3), then operate gear shift lever (4) to
FORWARD.
5. Operate fuel control lever (5) to raise the engine speed
gradually to full speed. (Keep the brake pedal depressed.)
6. Check that the machine does not move. This indicates that
brake performance is normal.
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4 - 39
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CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL 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.
When using engine oil service category CC class, change the engine oil and engine oil filter cartridge every 125 hours.
Refill capacity: 37 liters (9.78 US gal)

Prepare a socket wrench and filter wrench.
1. Remove covers (1) and (2) under the machine, then put
containers immediately underneath to catch the drained oil.
2. Insert a tool through hole (a) in the side face under the
machine, remove drain plug (P), and loosen drain valve (3)
slowly to drain the oil. Be careful not to get oil over yourself.
Be careful not to loosen drain valve (3) too much and deform
the stopper pin inside the valve.
3. Check the drained oil, if there is excessive metal particles or
foreign material, contact your Komatsu distributor.
4. After tightening drain valve (3), tighten drain plug (P).
Tightening torque for drain valve (3): 63.7 ± 14.7 N·m (6.5 ±
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1.5 kgf·m, 47.0 ± 10.8
lbft)
Tightening torque for drain plug (P): 68.6 ± 9.81 N·m (7 ± 1
kgf·m, 50.6 ± 7.2 lbft)
5. Using the filter wrench, turn filter cartridge (4) 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 to 1
turn.
4 - 40
.
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 (PAGE 3-42)".
Even if the machine has not been operated for 250 hours, the
oil and filter cartridge must be replaced when the machine has
been operated for 6 months.
In the same way, even if the machine has not been operated
for 6 months, the oil and filter cartridge must be replaced when
the machine has been operated for 250 hours.
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4 - 41
.
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
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.
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).
Remove all mud and soil from around oil level plug (G), and be
careful not to let any mud or soil get in when adding oil.
CHECK OIL LEVEL IN COUNTERWEIGHT TANK, ADD OIL
WARNING
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Immediately after operations, the oil is at high temperature. Wait for the temperature to go down before starting the operation.
When removing the oil filter cap, turn it slowly to release the internal pressure, then remove it carefully.
1. Stop the machine in a horizontal place.

2. Extend the counterweight and retract the cylinder, then set
counterweight control lever (2) to the N (HOLD) position.
3. Stop the engine, leave for approx. 2 to 3 minutes, then check
that the oil level is between the top and bottom red circles on
sight gauge (G).
If the oil level is below the bottom red circle, add engine oil
through oil filler (F).
4 - 42
.
REPLACE TRANSMISSION FILTER ELEMENT

1. Open engine side cover (1) on the left of the machine.
2. Remove mounting bolts (3) of filter (2), then remove cover (4).
3. Take out element (5).
4. Clean the inside of the case and the removed parts, then install
a new element. Always use a Komatsu genuine part for the
element.
5. Close engine side cover (1) on the left of the machine.
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4 - 43
.
REPLACE STEERING CLUTCH CASE FILTER ELEMENT

1. Open engine side cover (1) on the left of the machine.
2. Remove mounting bolts (3) of filter (2), then remove cover (4).
3. Take out element (5).
4. Clean the inside of the case and the removed parts, then install
a new element. Always use a Komatsu genuine part for the
element.
5. Close engine side cover (1) on the left of the machine.
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4 - 44
.

Maintenance for every 250 hours should be performed at the same time.
REPLACE FUEL FILTER CARTRIDGE
WARNING
After the engine has been operated, all parts are at high temperature, so do not replace the filter immediately. Wait for all parts
to cool down before starting the operation.
High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before
replacing the filter.
Do not bring any fire or flame close.
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.
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.
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Container to catch the oil
Filter wrench
1. Open the engine side cover on the left of the machine.
2. Set a container to catch the oil under the filter cartridge.
3. Using the filter wrench, turn filter cartridge (1) to the left and
remove it.
4. Clean the filter holder, fill the new filter cartridge with fuel, coat
the packing surface with the engine oil, and install to the filter
holder.
5. When installing, bringing the packing face into contact with the
filter holder seal surface, then tighten approx. 1/2 to 3/4 turns.
If the filter cartridge is tightened too much, the packing will be
damaged, and this will cause fuel leakage; if the filter cartridge
is not tightened enough, fuel will leak from the gap in the
packing. To prevent these problems, always tighten exactly to
the specified angle.
6. Loosen the knob of feed pump (2) and pump up and down
approx. 50 to 60 times to bleed the air.
7. Push in the knob of feed pump (2) and tighten it.
8. After replacing the filter cartridge, start the engine, and check
for fuel leakage from the filter seal surface. If any leakage is
found, repeat Steps (1) and (2) to remove the filter cartridge,
then check the packing surface for damage or embedded
foreign material.
If any damage or embedded foreign material is found, replace
the packing with a new packing, then repeat Steps (3) to (6).
4 - 45
.
CLEAN FINAL DRIVE CASE BREATHER

Remove the breather, then rinse in clean diesel oil or flushing oil to
remove the dirt. (2 places)
REMARK
There are 2 final drive case breathers (on the bottom left and right
of the fuel tank). The center breather is the breather for the
steering clutch case.
CLEAN STEERING CLUTCH CASE BREATHER

remove the dirt. (1 place)
REMARK
The steering clutch case breather is the center breather of the
three breathers at the bottom of the fuel tank. The left and right
breathers are the breathers for the final drive case.
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CLEAN WINCH CASE BREATHER
remove the dirt. (1 place)
4 - 46
.

Maintenance for every 250 and 500 hours should be performed at the same time.
CHANGE OIL IN STEERING CLUTCH CASE (INCLUDING TRANSMISSION CASE, TORQUE CONVERTER CASE),
CLEAN STRAINER
WARNING
the operation.
The undercover is heavy. Never open and close operation right below the undercover. When removing bolts, work behind the
right below and be ready for escaping at any time.

1. Remove drain plug (1) from the steering clutch case under the
machine, drain the oil, then tighten the drain plug again.
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2. Remove drain plug (2) from the torque converter case under
the machine, drain the oil, then tighten the drain plug again.
4 - 47
.
3. Remove the floor cover at the front of the operator's seat,

remove bolt (3), then remove cover (4).
Take out steering clutch case strainer (5) and magnet (6).
If strainer (5) or magnet (6) are damaged, replace with a new
part.
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4. Remove bolts (7) under the machine, then take out the torque
converter strainer together with cover (8).
5. Remove all dirt from strainer, then wash in clean diesel oil or
flushing oil.
Clean the case interior and the removed parts.
6. Install the strainers to their original position.
7. After installing, replace the elements of the transmission filter
and the steering clutch case filter. For details, see "REPLACE
TRANSMISSION FILTER ELEMENT (PAGE 4-43)".
8. Refill the specified quantity of engine oil through oil filler (F).
9. After adding oil, check that the oil is at the specified level. For
details, see "CHECK OIL LEVEL IN STEERING CLUTCH
CASE (INCLUDING TRANSMISSION, TORQUE
CONVERTER CASE), ADD OIL (PAGE 3-43)".
4 - 48
.
CHANGE OIL IN FINAL DRIVE CASE
WARNING
the operation.
Refill capacity: 68 liters (17.97 US gal) (left and right, each)

1. Remove the sprocket outside cover, then remove drain plug
(1) of the planet gear chamber, drive the machine forward or in
reverse to set drain plug (1) at the bottom, then drain the oil
from the planet gear chamber.
2. Remove drain plug (2) of the spur gear chamber, drain the oil,
then tighten the drain plug again.
3. Set the position of drain plug (1) of the planet gear chamber so
that it is horizontal with the center of the sprocket axle, then
add engine oil (CD class SAE30, regardless of the ambient
temperature) through the hole of drain plug (1) until it
overflows. Repeat the procedure on the other side.
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4. After refilling with oil, tighten drain plug (1).
5. Add engine oil (CD class SAE30, regardless of the ambient
temperature) through the hole of drain plug (1) until it
overflows. Repeat the procedure on the other side.
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.
CHANGE OIL IN WINCH CASE, CLEAN STRAINER

1. Remove the undercover under the winch case.
2. Remove drain plug (1), then connect the drain hose.

Part No. of drain hose: 196-98-22100
3. Insert the tool from the top of the frame and loosen drain valve
(2).
4. Drain the oil, then remove the drain hose and tighten drain plug
(1) and drain valve (2).
Tightening torque of drain plug (1):
58.8 to 78.5 N·m (6 to 8 kgf·m, 43.4 to 57.9 lbft)
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Tightening torque of drain plug (2):
49 to 78.5 N·m (5 to 8 kgf·m, 49.0 to 57.9 lbft)
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.
5. Remove bolts (3) and cover (4), then take out winch case
strainer (5) and magnet (6).
6. Clean the inside of the case and the removed parts, then clean
the strainer and assemble in the original position. If the strainer
is broken, replace it with a new part.
7. Add the specified amount of engine oil through oil filler port (F).
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4 - 51
.
CHECK, CLEAN FUEL STRAINER

1. Remove cover (1) under the fuel tank at the rear of the
machine.
2. Close fuel supply valve (2).
3. Remove cap (3), then wash the strainer and strainer case.
The strainer forms one unit with cap (3).
4. After checking and cleaning, install the strainer, then tighten
cap (3).
5. Install the strainer, then open fuel supply valve (2).
6. Install cover (1).
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CHECK OIL IN UNDERCARRIAGE PARTS
Stop the machine on flat ground and check the oil level in the track rollers, carrier rollers, and idler as follows.
1. Loosen the seal bolt slowly. If oil oozes out from the thread,
there is no problem with the oil level, so tighten the bolt again
immediately.
2. If no oil comes out even when the seal bolt is loosened, the oil
level is low, so add oil.
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.
CHECK OIL LEVEL IN RECOIL SPRING CASE, ADD OIL

1. Remove plug (P) and check that the oil level is up to near the
bottom edge of the plug hole. If the oil level is low, add engine
oil through plug (P).
REMARK
The engine oil acts to prevent the spring from rusting, so waste oil
(oil drain from the final drive case) can be used.
CHECK, CLEAN RADIATOR FIN

1. Use compressed air to blow off the mud, dirt, or leaves
clogging the radiator core. Steam or water can be used instead
of compressed air.
REMARK
Next, check the rubber hoses, and if they are cracked or brittle,
replace them.
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Check also that there are no loose hose clamps.
4 - 53
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LUBRICATING
Apply grease through the grease fittings marked by arrows.
1. Universal joint (2 places)
2. Idler adjustment rod (2 places)
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3. Tension pulley assembly (1 place)
4 - 54
.
REPLACE CORROSION RESISTOR CARTRIDGE
WARNING
If the engine has been operated, all parts will be at a high temperature, so never try to replace the cartridge immediately after
stopping the engine.
Always wait for the engine and other parts to cool down.
Container to catch drained coolant

Prepare a filter wrench for fuel filter element.
1. Tighten 2 valves (1).
2. Set a container to catch the coolant under the cartridge.
3. Using a filter wrench, remove cartridge (2).
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.
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If the filter cartridge is too loose, coolant will also leak from the
packing, so always tighten to the correct amount.
6. Open valves (1) (2 places).
7. After replacing the cartridge, start the engine and check for any
coolant leakage from the filter seal surface. If there is any
leakage, check if the cartridge is tightened properly.
CHECK TIGHTENING PARTS OF TURBOCHARGER

Contact your Komatsu distributor to have the tightening portions checked.
4 - 55
.

Maintenance for every 250, 500, and 1000 hours should be performed at the same time.
LUBRICATING
Apply grease through the grease fittings marked by arrows.
1. Fuel control lever shaft (2 places)
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2. Steering lever shaft (8 places)
4 - 56
.
3. Gear shift lever shaft (4 places)
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4. Winch control lever shaft (9 places)
5. Counterweight lever shaft (3 places)
4 - 57
.
6. Boom control lever shaft (2 places)
7. Boom kick-out (2 places)
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4 - 58
.
CHANGE OIL IN COUNTERWEIGHT TANK, REPLACE FILTER ELEMENT
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 carefully.

1. Operate the counterweight control lever, extend the
counterweight, then return the lever to the HOLD position and
stop the engine. Turn the cap of oil filler port (F) slowly to
release the pressure, then remove the cap.
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2. Remove drain plug (1) under the tank, drain the oil, then tighten
drain plug (1) again.
When loosening drain plug (1), be careful not to get oil on
yourself.
4 - 59
.
3. Remove bolts (3), then remove cover (4), and take out element
(5).
4. Clean the inside of case and removed parts and install a new
element.
5. Refill the specified quantity of engine oil through oil filler (F).
6. After adding oil, check that the oil is at the specified level. For
details, see "CHECK OIL LEVEL IN COUNTERWEIGHT
TANK, ADD OIL (PAGE 3-44))".
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4 - 60
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CLEAN ENGINE BREATHER ELEMENT

1. Loosen clamp (1), then remove the hose.
2. Remove bolt (2), then remove breather (3).
3. Wash the whole breather in diesel oil or flushing oil, then blow
it dry with compressed air.
4. Replace the breather O-ring with a new part, coat with engine
oil, and install it.
Check the breather hose, and if there is any oil sludge on the
inside, replace it with a new hose.
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CLEAN AND CHECK TUTBOCHARGER
Contact your Komatsu distributor for cleaning and inspection.
CHECK PLAY OF TURBOCHARGER ROTOR

Contact your Komatsu distributor to have the rotor play checked.
CHECK ALTERNATOR, STARTING MOTOR

The brushes mat be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspection
and repairs.
If the engine is started frequently, have this inspection carried out every 1000 hours.
CHECK ENGINE VALVE CLEARANCE, ADJUST

Special tools are required for removial and adjustment of the parts, have your Komatsu distributor perform this
service.
4 - 61
.

Maintenance for every 250, 500, 1000, and 2000 hours should be performed at the same time.
CHECK WATER PUMP

Check that there is no oil leakage, water leakage, or clogging of the
drain hole (1). If any abnormality is found, contact your Komatsu
distributor for disassembly and repair or replacement.
CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of
the vibration damper (1).
If any cracks or peeling are found, contact your Komatsu distributor
to have the parts replaced.
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CHECK FAN PULLEY AND TENSION PULLEY
Check the pulley for play and leakage of grease. If there is any
abnormality, please contact your Komatsu distributor for
disassembly and repair or replacement.
4 - 62
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5-1
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SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Item Unit D355C-3
Operating weight (without operator) kg (lb) 58100 (128111)*1
Boom unit weight

kg (lb) 2420 (5336)
[length 7300 mm (23 ft 11 in)]
Counterweight unit weight
kg (lb) 12900 (28445)
(including cylinder, weight)
Name of engine - KOMATSU SA6D140E-2 diesel engine
Engine horsepower KW (HP)/rpm 360/2,000
A Overall length mm (ft in) 6,030
B Overall height mm (ft in) 8,100
Overall width
C (To boom mount when counterweight mm (ft in) 4,405
is retracted)
Forward km/h (MPH) 3.3/5.9/9.8
Travel speed (1st/2nd/3rd)
Reverse km/h (MPH) 3.9/7.0/11.0
Raise m/min 5.5/12.7
Boom speed (LOW/Hi)
Lower m/min 4.5/10.2
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*1: With 860 mm (34 in) shoe, cab
5-2
.
SPECIFICATIONS LIFTING LOAD CAPACITY CURVE
LIFTING LOAD CAPACITY CURVE

Equipment
Diameter 20 mm (0.8 in) wire rope, minimum cutting load 27600kg (60858 lb)
Wire rope for hook, 6 loops
Wire rope for boom, 5 loops
When counterweight extended load is 9230 kg (20352 lb)
Including pulley efficiency
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5-3
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6-1
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GENERAL PRECAUTIONS ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS
PRECAUTIONS RELATED TO SAFETY
If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the
machine, but will also cause problems with safety.
When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distributor
first.
If you do not contact Komatsu, we cannot accept any responsibility for any accidents or failures.
WARNING
General precautions
Read the instruction manual for the attachment carefully, and do not use the machine before you understand the operation
method completely.
If you lose the instruction manual, be sure to order another copy from your Komatsu distributor.
To prevent serious personal injury caused by misoperation, place your foot on the pedal only when operating the pedal.
Precautions for removal and installation
When removing or installing an attachment, observe the following items and work safely.
Select a firm, level surface when installing or removing an attachment.
When working in cooperation with one or more other workers, decide signs and observe them when carrying out the operation.
When carrying a heavy part (25 kg (55 lb) or more), use a crane.
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When removing a heavy part, always place a support in position before removing it.
When lifting a load with a crane, be particularly careful of the center of gravity.
It is dangerous to carry out operations when the load has been raised by a crane. Always lower the load onto a stand and check
that it is safe.
When leaving an attachment removed or installing it, place it in a stable position to prevent it from falling over.
Never go under a load raised by a crane.
Always stand in a place which is safe even if the load should fall.
NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified person.
For details of removal and installation operations, contact your Komatsu distributor.
6-2
.
ATTACHMENTS, OPTIONS USING SEAT BELT
USING SEAT BELT

Always use the seat belt when operating the machine.
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 manufacture of the belt is shown
on the back of the belt.
Adjust and fasten the seat belt before operating the machine.
Always use the seat belt when operating the machine.
Fit the seat belt across your lap without twisting.
HANDLING SEAT BELT

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

6. When removing the belt, press the red button on buckle (3).
The belt will automatically be wound in.
Check the seat belt mounting bolts and re-tighten if necessary.
Tightening torque: 24.5 ± 4.9 N·m (2.5 ± 0.5 kgf·m, 18.1 ± 3.6 lbft)
If the seat belt is scratched or frayed, if any fittings are broken or deformed from long service, replace the seat belt
immediately.
6-3
.
SELECTION OF TRACK SHOE ATTACHMENTS, OPTIONS
SELECTION OF TRACK SHOE

SELECTION OF TRACK SHOES
Select suitable track shoes to match the operating conditions.
METHOD OF SELECTING SHOES

If a wider shoe than necessary is used, the load on the track will increase, and this will cause the shoes to bend, links
to crack, pins to break, shoe bolts to come loose, and various other problems.
Category Use Precautions when using Track shoe width

Normal
A There is no particular limit to its use. 860 mm (34 in)
soil
Use this shoe on soft ground where the shoe in category A sinks 960 mm (38 in),
B Soft soil
into the ground. 1010 mm (40 in)
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6-4
.
ATTACHMENTS, OPTIONS CAP WITH LOCK, HANDLING
CAP WITH LOCK, HANDLING

METHOD OF OPENING AND CLOSING CAP WITH LOCK
Lock-type caps are available for the radiator water filler, fuel tank filler cap, power train case oil filler cap, hydraulic
tank oil filler cap, and hydraulic tank breather cap. The method of opening or closing the cap is as follows.
TO OPEN THE CAP

1. Insert the key. Make sure that you have inserted the key fully
before turning it. If the key is turned when only partially
inserted, it may break.
2. Turn the key counterclockwise to align the match mark on the
cap with the rotor groove, then turn the cap slowly. When a
click is heard, the lock is released, enabling the cap to be
opened.
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TO LOCK THE CAP

1. Turn the cap into place.
2. Turn the key clockwise and take the key out.
6-5
.
EXTERNAL POWER SOURCE ENGINE PREHEATING HEATER ATTACHMENTS, OPTIONS
EXTERNAL POWER SOURCE ENGINE PREHEATING HEATER

This engine preheater is an engine starting aid to be used in a season when the ambient temperature goes down
below -20°C (-4°F), or when it is difficult to start the cold engine though the ambient temperature stays above -20°
C (-4°F).
Use an external power supply (single phase, 230V AC) to heat up the engine cooling water, the engine oil pan oil,
and the power train oil. This makes it easier to start the engine.
PROCEDURE FOR SETTING UP EXTERNAL POWER SOURCE

1. When using this preheating heater, it is necessary to provide the following external power source (1).
For details, see Step 3.
2. It is necessary to make external power supply input cable (2)
locally to bring the electricity from external power supply (1) to
the receptacle installed to the machine.
For details of the procedure for making the cable, see step 4.
3. External power supply input cable (2) is the power cable used
to bring electricity from local external power supply (1) to the
input receptacle on the machine. Connect as shown in the
diagram to operate the preheating heater.
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REMARK
The electric leakage breaker is installed to prevent danger of electrocution if the electrical supply leaks to the
machine.
The ground cable is connected to the ground for the same reason.
This is to prevent any drop in voltage.
6-6
.
ATTACHMENTS, OPTIONS EXTERNAL POWER SOURCE ENGINE PREHEATING HEATER
4. Manufacturing external power source input cable

The external power source input cable must be manufactured locally to match the local conditions. This does
not mean that any cable can be used.
Manufacture the cable as follows.
1) For the wiring, purchase three-core chloroprene sheath
cab tire cable locally.
The nominal cross-sectional area of one core should be
5 to 8 mm2.
For the voltage resistance function, it should be able to
withstand 3000 volts for 1 minute.
To prevent any drop in voltage, make the length less
than 30 m (98 ft 5 in).
2) Connect the chassis input side plug (shipped as individual
part) 175-06-37871 to the tip of the cable.
The plug has three contacts and each contact is marked
Contact
with a symbol. Connect each of the 3 core wires of the Core wire to connect
symbol
cable to its respective contact.
When connecting, solder each core wire to its contact. A Ground circuit wire
To prevent short-circuiting through the conductor, B Power source circuit wire
insulate the soldered portion with a rubber tube or tape.
C Power source circuit wire
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Always use part No. 175-06-37871 for the plug.
If any other plug is used, it will be impossible to connect
to the external power input receptacle.
6-7
.
3) Modify the other end of the cable so that it can be connected to the power supply.
After completing the modification of the connection, the external power source input cable is completed.
The length should be less than 30 m (98 ft 5 in).
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A: To power supply to the input socket (receptacle) on the machine.
B: To power supply
5. Establishing power supply
WARNING
When setting up the power supply equipment, follow all the related laws and regulations in that country and use an authorized
contractor.
1) Power supply equipment is needed to use this preheater. The power supply equipment is used to supply
AC voltage sent from the transformer substation or generator to the preheater. It must have a structure that
enables the external power source input cable to be connected easily.
2) The shape, size, and method of setting up depend on the local area, but make the specifications as follows.
Note that there is no switch or safety device provided on the machine.
Specifications for power supply equipment
Type of output electricity: Single-phase alternating current
Output voltage: 230 volts (V)
Supply capacity: 8.5 kilovolt amperes (kVA)
Main switch: Yes
Electric leakage breaker: Yes
Ground circuit: Yes
6-8
.
System diagram, overall wiring diagram (for reference when carrying out the work)
System diagram for external power supply type engine preheater
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(1) Cylinder block heater (1500W) A. Ground

(2) Oil heater (600W) B. Power supply
(3) Plug (175-06-37871) C. Power supply
(4) Input receptacle on machine
REMARK
Letters A, B, and C on the external power supply input cable are at the same as the letters on the input receptacle
on the machine.
6-9
.
Overall wiring diagram for external power supply type engine preheater
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6 - 10
.
PROCEDURE FOR HANDLING EXTERNAL POWER SUPPLY

Use this engine preheater in a season when the ambient temperature goes down below - 20°C, or when it is difficult
to start the cold engine though the ambient temperature stays above - 20°C.
NOTICE
For details of the oil to use, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE
4-8)".
Method of operating
WARNING
Always lower the work equipment completely to the ground.
Always wipe off any oil or fuel on the preheater or nearby parts.
Always remove dry leaves or other flammable materials accumulated inside the engine room.
Always check that the engine oil and engine coolant are at the specified level.
Before passing electricity through the preheater, check that there is no damage to the covering of the wires. If any damage is
found, replace or repair the wire.
WARNING
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Never connect the cables after the power switch has been turned ON. This is dangerous.
Check that the grounding wiring is properly grounded before turning the power switch ON.
1. If it is anticipated when finishing the day's work that the engine preheater will be used again at the next run, park
the machine within the reach of the power unit with an external power input cable.
NOTICE
Park the machine on level ground.
Take action to prevent the track shoes from freezing and sticking to the ground surface.
Covering the machine will make it easier to start the engine.
6 - 11
.
2. Turn the power for the preheater on several hours before

starting the engine to warm up the coolant and oil in the engine
oil pan.
1) Connect external power supply (1) and input receptacle (2)
on the machine.
The input receptacle on the machine is installed inside the
fender cover on the left side of the machine.
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2) Use the standby switch (if available) or the power switch (main switch) on the power supply equipment to
start the supply of electricity.
Never connect the cables after the power switch has been turned ON. This is dangerous.
Check that the grounding wiring is properly grounded before turning the power switch ON.
6 - 12
.
3. The time to keep the electricity on differs according to the ambient temperature and the type of oil being used.
If the ambient temperature is below - 15°C, turn on the electricity immediately after stopping the engine on the
previous day to maintain the engine temperature.
NOTICE
When carrying out the warming-up operation in ambient temperatures below 0°C, see " (PAGE 888-888)".
If the ambient temperature is above 0°C, turn off the electricity. If the electricity is left on, the oil temperature will become too
high and this will cause deterioration of the oil.
If the ambient temperature is below - 20°C and the engine is stopped for more than 2 hours, use this preheater to maintain the
temperature.
4. When preheating work is finished, turn off the power switch, disconnect the cable and screw a protective cap
in the power input outlet (receptacle) on the machine side securely.
5. Start the engine.
NOTICE
Do not start the engine while the electricity is turned on. Always turn the power switch OFF before starting the engine. If the
engine is started with the electricity still turned on, it will cause failure of the coolant heater.
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6 - 13
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INDEX
INDEX
<A> GENERAL VIEW OF CONTROLS AND

AIR CONDITIONER, HANDLING 3- 33 GAUGES 3- 3
ASHTRAY 3- 32 GENERAL VIEW OF MACHINE 3- 2
GUIDES TO MAINTETNANCE 4- 2
<B>
BREAKING IN THE MACHINE 1- 7 <H>
HANDLING OIL, FUEL, COOLANT, AND
<C> PERFORMING OIL CLINIC 4- 4
CAP WITH LOCK, HANDLING 6- 5 HEATER, HANDLING 3- 37
METHOD OF OPENING AND CLOSING
CAP WITH LOCK 6- 5 <I>
CHECK AFTER FINISHING WORK 3- 74 INTRODUCTION 1- 7
CHECK AFTER STOPPING ENGINE 3- 74
CHECK BEFORE STARTING ENGINE, <L>
ADJUST 3- 38 LIFTING LOAD CAPACITY CURVE 5- 3
COLD WEATHER OPERATION 3- 85 LOAD LIMITS FOR MACHINE 3- 77
AFTER COLD WEATHER 3- 87 LOADING, UNLOADING WORK 3- 77
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AFTER COMPLETION OF WORK 3- 87 LOCKING 3- 74
PRECAUTIONS FOR LOW LONG-TERM STORAGE 3- 88
TEMPERATURE 3- 85 AFTER STORAGE 3- 88
CONTROL LEVERS, PEDALS 3- 19 BEFORE STORAGE 3- 88
DURING STORAGE 3- 88
<E>
ENGINE SERIAL NO. PLATE AND <M>
POSITION 1- 8 MACHINE SERIAL NO. PLATE AND
EXPLANATION OF COMPONENTS 3- 5 POSITION 1- 8
EXTERNAL POWER SOURCE ENGINE MAINTENANCE SCHEDULE CHART 4- 15
PREHEATING HEATER 6- 6 METHOD OF LIFTING MACHINE 3- 78
PROCEDURE FOR HANDLING MOVING MACHINE OFF 3- 62
EXTERNAL POWER SUPPLY 6- 11
PROCEDURE FOR SETTING UP <N>
EXTERNAL POWER SOURCE 6- 6 NECESSARY INFORMATION 1- 8
<F> <O>
FOREWORD 1- 2 OPERATION 3- 38
FRONT PANEL 3- 5 OPERATIONS AND CHECKS AFTER
FRONT/REAR, LEFT/RIGHT DIRECTIONS STARTING ENGINE (NORMAL, IN COLD
OF MACHINE 1- 7 WEATHER) 3- 58
FUSE BOX 3- 31 OUTLINE OF ELECTRIC SYSTEM 4- 6
OUTLINES OF SERVICE 4- 4
<G>
GENERAL PRECAUTIONS 2- 8 <P>
GENERAL PRECAUTIONS 6- 2 PARKING MACHINE 3- 72
PRECAUTIONS RELATED TO PERIODIC REPLACEMENT OF SAFETY
SAFETY 6- 2 CRITICAL PARTS 4- 14
GENERAL VIEW 3- 2 POSITIONF OF SERVICE METER 1- 9
PRECAUTIONS FOR LOADING 3- 77
7-1
.
INDEX
PRECAUTIONS FOR MAINTENANCE 2- 25 <T>

PRECAUTIONS FOR OPERATION 2- 16 TABLE TO ENTER SERIAL NO. AND
BATTERY 2- 22 DISTRIBUTOR 1- 9
BEFORE STARTING ENGINE 2- 16 TIPS FOR LONGER UNDERCARRIAGE
OPERATION 2- 18 LIFE 3- 75
TOWING 2- 24 TOOL BOX 3- 32
TRANSPORTATION 2- 21 TORQUE LIST 4- 13
PRECAUTIONS FOR OPERATION 3- 70 TRANSPORTATION 3- 77
PRECAUTIONS FOR TRANSPORTATION PROCEDURE 3- 77
TRANSPORTATION 3- 78 TRAVELING ON ROADS 3- 78
PROCEDURE FOR REMOVAL AND TROUBLESHOOTING 3- 89
INSTALLATION OF BOOM 3- 81 AFTER RUNNING OUT OF FUEL 3- 89
PROCEDURE FOR REMOVAL AND IF BATTERY IS DISCHARGED 3- 90
INSTALLATION OF CAB 3- 79 METHOD OF TOWING MACHINE 3- 89
PROCEDURE FOR REMOVAL AND OTHER TROUBLE 3- 93
INSTALLATION OF COUNTERWEIGHT 3- 83
<U>
<S> USE OF FUEL, COOLANT AND
SAFETY 2- 2 LUBRICANTS ACCORDING TO
SAFETY CRITICAL PARTS 4- 14 AMBIENT TEMPERATURE 4- 8
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SAFETY INFORMATION 1- 5 PROPER SELECTION OF FUEL,
SAFETY LABELS 2- 4 COOLANT AND LUBRICANTS 4- 8
CONTENT AND USE OF WARNING USING SEAT BELT 6- 3
PLATES 2- 7 HANDLING SEAT BELT 6- 3
POSITIONS OF SAFETY
PICTOGRAMS 2- 4 <W>
SAFETY LABELS 2- 5 WEAR PARTS LIST 4- 7
SELECTION OF TRACK SHOE 6- 4 WEAR PARTS LIST 4- 7
SELECTION OF TRACK SHOES 6- 4
SERVICE PROCEDURE 4- 17
INITIAL 250 HOURS SERVICE (ONLY
AFTER THE FIRST 250 HOURS) 4- 17
WHEN REQUIRED 4- 18
SHIFTING BETWEEN FORWARD AND
REVERSE 3- 65
SHIFTING GEAR 3- 64
SPECIFICATIONS 5- 2
STANDARD TIGHTENING TORQUES
FOR BOLTS AND NUTS 4- 13
STARTING ENGINE (NORMAL, IN COLD
WEATHER) 3- 55
STEERING MACHINE 3- 66
STOPPING ENGINE 3- 61
STOPPING MACHINE 3- 64
SWITCHES 3- 14
7-2
.
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D355C-3 PIPELAYER
Form No. SEAM051400P
©
2004 KOMATSU
All Rights Reserved
Printed in Japan 11-04

D355c-3 Maintenance and Operation

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D355c-3 Maintenance and Operation

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Location to Keep Operation & Maintenance Manual

FOREWORD SAFETY INFORMATION

Other signal words

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

SAFETY INFORMATION FOREWORD

Example of safety label using words

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE

BREAKING IN THE MACHINE

NECESSARY INFORMATION FOREWORD

MACHINE SERIAL NO. PLATE AND POSITION

FOREWORD NECESSARY INFORMATION

POSITION OF SERVICE METER

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.

Machine serial No.

EVERY 1000 HOURS SERVICE 4- 47

Precautions for Operation 2- 16

Precautions for Maintenance 2- 25

SAFETY LABELS SAFETY

POSITIONS OF SAFETY PICTOGRAMS

SAFETY SAFETY LABELS

(2) Caution when traveling in reverse (09802-B0750)

SAFETY LABELS SAFETY

(4) Caution for high temperature coolant and hydraulic oil

(5) Caution for check and adjust track tension (09657-A0881)

SAFETY SAFETY LABELS

(7) Caution to stop engine when carrying out inspection and

(8) Caution about going close when machine is moving

CONTENT AND USE OF WARNING PLATES

GENERAL PRECAUTIONS SAFETY

IF ABNORMALITIES ARE FOUND

CLOTHING AND PERSONAL PROTECTIVE ITEMS

FIRE EXTINGUISHER AND FIRST AID KIT

SAFETY GENERAL PRECAUTIONS

KEEP MACHINE CLEAN

INSIDE OPERATOR'S COMPARTMENT

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT

Before leaving the machine, always stow the work equipment,

GENERAL PRECAUTIONS SAFETY

HANDRAILS AND STEPS

MOUNTING AND DISMOUNTING

SAFETY GENERAL PRECAUTIONS

GENERAL PRECAUTIONS SAFETY

Fire caused by accumulation of flammable material.

Fire coming from electric wiring

Fire coming from hydraulic line

Explosion caused by lighting equipment

ACTION IF FIRE OCCURS

WINDOW WASHER LIQUID

PRECAUTIONS FOR ATTACHMENTS

CAB WINDOW GLASSES

SAFETY GENERAL PRECAUTIONS

WORKING ON LOOSE GROUND

GENERAL PRECAUTIONS SAFETY

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

ENSURE GOOD VISIBILITY

VENTILATION FOR ENCLOSED AREAS

SAFETY GENERAL PRECAUTIONS

CHECKING SIGNALMAN'S SIGNALS AND SIGNS

BE CAREFUL ABOUT ASBESTOS DUST

PRECAUTIONS FOR OPERATION SAFETY

PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN STARTING