Operation & Maintenance Manual: Bulldozer

SEAM000301
Operatio&nMaintenance
Manual
BULLDOZER
SERIAL NUMBERS
D275A -1 OOOland up
FOREWORD
FOREWORD
This manual describes procedures for operation, handling, lubrication, main-
tenance, checking, and adjustment. It will help the operator or anyone realize
peak performance through effective, economical and safe machine operation
and maintenance.
Before operating this machine, read this manual thoroughly and make sure
that you understand its contents.
Failure to follow the instructions given in this manual may lead to a serious
failure.
Please continue studying this manual until proper operation is completely re-
inforced into personal habit.
This manual describes the basic techniques. Skill is performed as the
operator or anyone get the correct knowledge and performance of the
machine.
Operation, inspection, and maintenance should be carefully carried out, and
the safety must be given the first priority. Safety precautions are
indicated with A marks and technical precautions with * marks in this ma-
nual. The safety information contained in this manual is intended only to
supplement safety codes, insurance requirements, local laws, rules and
regulations.
Some illustration pictures are different from your machine as technical im-
provement is continuously reflected on it. Revision to up-to-date manual’s
content is performed in later editions.
This operation & maintenance manual may contain attachments and
optional equipment that are not available in your area. Please consult your
local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
- o-1 -
EXPLANATION OF SYMBOLS
BREAKING IN YOUR NEW MACHINE
EXPLANATION OF SYMBOLS
Always be particularly careful to pay attention to the information in this ma-
nual marked with the following symbols.
A This symbol indicates a warning about safety. It gives warning that there is
danger of personal injury.
If you see this symbol in the operation and maintenance manual, pay care-
ful attention to safety, and always take the action given to ensure safety in
operation and maintenance.
*
This symbol indicates that care is to be taken. It gives information that will
help maintain to the machine in good condition and to carry out the oper-
ation efficiently.
Always read the information given.
BREAKING IN YOUR NEW MACHINE

Each machine is carefully adjusted and tested before shipment. However, a
new machine requires careful operation during the first 100 hours to break in
the various parts.
If a machine is subjected to unreasonably hard use at the initial operation
stage, the potential of performance will prematurely deteriorate and the service
life will be reduced. A new machine must be operated with care, particularly
with regard to the following items.
After starting, let the engine idle for 5 minutes to allow proper engine warm-
up prior to actual operation.
Avoid operation with heavy loads or at high speeds.
Sudden starting or acceleration, unnecessarily abrupt braking and sharp turn-
ing should be avoided.
If the machine is delivered without any cooling water in the radiator, flush
the cooling system .with ample clean water to clean the system, then fill the
radiator with cooling water.
When replacing oil filter elements (cartridges), check their interiors for dirt
and dust. If heavily collected, check for possible cause before starting
operation.
Hours of operation are indicated by the service meter.
- o-2 -
CONTENTS
I FOREWORD o-1
/EXPLANATION OF SYMBOLS o-2
I BREAKING IN YOUR NEW MACHINE o-2
/ SAFETY HINTS. . . A l-l
/OPERATION 2-l
/ MAINTENANCE . 3-l
I OPERATING INSTRUMENTS 4-l

~-
/ dPTlONAL PARTS, ATTACHMENT 5-l
TROUBLE SHOOTING GUIDE 6-l
/ SERVICE METER, SERIAL NUMBERS, LUBRICANTS 7-l
- o-3 -
MEMO
- o-4 -
SAFETY HINTS. . . A
SAFETY HINTS l l l A
OPERATION ................................................................ l- 2
MAINTENANCE ............................................................. l-16
POSITION FOR STICKING CAUTION AND NAME PLATES ..................... 1-21
-l-l-
SAFETY HINTS . . . A
OPERATION
GENERAL I *..‘I..,
0 Wear well-fitting helmet, safety shoes and
working clothes. If the nature of the work
requires safety, wear protective goggles or
mask, thick gloves, ear plugs or other
protection.
0 Wear proper clothes.
Do not let your clothes get caught on a
protruding part of the machine.
Do not wear oily clothes since they are
likely to catch fire.
0 Accidents or injuries are liable to occur
when the operator is careless or slack. It is
most important to bear safe operation in’
mind at all times.
a Take care of your health. Do not drive
when tired, or after drinking.
0 Learn the prohibitions, cautions and rules
about work procedures in the work site.
When there is a leader, fix standard signals
and always follow these signals when
operating.
l If there should be an accident or fire or
any other such unexpected mishap, deal
with it quickly, using the nearest apparatus.
Learn beforehand the locations of the first
aid boxes and fire extinguishers and how
to use them. It is also important to know
the emergency contact system.
l Learn about the safety devices on your
own machine and about how to use them.
Confirm that they are correctly attached in
the prescribed position.
Such safety devices include:
Guards
Canopies
Protective Devices
Roller-Over Protective Structures
Seat Belts, etc.
-1-2-
SAFETY HINTS. . . A
Read the Operation and Maintenance Ma-

nual carefully. Learn how to use the con-
trol devices, gauges and warning devices.
Be sure you understand the meaning of
the caution plates. Remember the check
points and checking method for engine oil,
fuel, cooling water and hydraulic oil levels.
Exhaust gas is dangerous. When running

the engine for long periods in a poorly
ventilated area, there is a danger of gas
poisoning, so open the windows or doors
to ensure a good supply of fresh air.
I Guw9
When operating inside a building always be

I
A
_-A
sure of the clearances of the ceiling, en- _..
trances, aisles, etc. and the load limit of

the floor.
When operating on a road, provide a traffic
director or enclosure. -
Never allow other person than the operator
to ride on the machine during operation.
Do not allow an open flame to come near

fuel or oil.
Bringing an open flame such as a lighted
cigarette or match near flammable material
may start a fire.
-f-3-
SAFETY HINTS. . . A
BEFORE STARTING OPERATION

0 Examine the lay of the land and the kind
of soil at the work site to determine the
dangerous points and the best method of
operation.
Proceed with the work only after making
safety arrangements about the dangerous
points.
0 install the overhead guard.
In places where there is danger of falling
stones or other objects, always install the
overhead guard.
a Install ROPS and seat belt.
In places where there is danger of falling
rocks or danger of the machine rolling
over, always install the ROPS and seat belt.
0 Never modify ROPS.
Please contact your Komatsu distributor for
modification.
0 Inspect leakages from the fuel, lubricating
and hydraulic systems. Repair any fuel or
oil leakage, and wipe off all dirty oil. Check
that the shoe bolts are not loose, and that
no other parts are damaged or missing.
Machine having such failures should not be
operated.
l When getting on or off the machine, use

the handrail and step provided. Do not
jump up or down from the machine.
- 1-4-
SAFETY HINTS. . . A
Do not leave parts or tools lying around in

the vicinity of or on the floor of the oper-
ator’s comopartment. Keep everything in its
proper place.
Wipe off throughly any grease, oil or mud
on the step, handrail, floor or control le-
vers. Failure to do this may cause you to
slip.
Check the level of the fuel, lubricants and

cooling water. Extinguish cigarettes before
checking or replenishing. Check that the
radiator cap and each oil filler caps or
plugs are firmly tightened.
Adjust the operator’s seat until it is in the
most comfortable position for operating. Al-
ways sit in the seat while operating. Do
not operate the machine from any other
position.
Adjust the seat so that the brake pedal can
be depressed all the way with the oper-
ator’s back against the backrest.
Before operating the machine, check and
fasten the seat belt.
Inspect the seat belt and fittings, replace
any damaged or worn parts.
l To ensure the safety of workers near the

machine, always sound the horn to warn
them before starting the engine and mov-
ing the machine. Be particularly careful to
check that the rear is clear before backing
the machine. If necessan/, position a
flagman.
l Combustible objects such as pieces of
wood, dead leaves, and pieces of paper
may cause fire, so inspect the inside of the
engine room and remove them.
l Before starting the engine, confirm that all
control levers are in “NEUTRAL” or
“HOLD”.
- 1-5-
SAFETY HINTS. . . A
AFTER STARTING THE ENGINE t ‘-.

Confirm that ail gauges and warning de-
vices are functioning correctly, and that the
gauge readings are within the prescribed
range.
Check the play and travel of each lever
and pedal.
Operate the blade and ripper to confirm

that they are functioning normally.
0 Move the machine slowly and listen care-

fully to the engine or gears to confirm that
they are not making any unusual noises.
Operate the gear shift lever to confirm that
the travel speeds for forward and reverse
are functioning normally. Also carry out a
brake test at each travel speed.
l Choosing a safe place, turn the machine to

the left and right to confirm that the steer-
ing devices are functioning normally.
0 if these tests reveal anything wrong, how-
ever slight it may be, contact the man in
charge of the machine and operate the
machine only after obtaining his
permission.
- I-6-
SAFETY HINTS _ . . A
DURING OPERATION
+c-
l Always concentrate. It is extremely danger- r-:-p)
ous to allow yourself to be distracted or to ,,;;;y
....
think of other things when operating a .. 4’ :
machine. .,i
.;;; T‘ru
,
*y/ +,
In dangerous places, or where there is re- L
c .
stricted visibility, it is important to get
down from the machine and confirm \
whether it is safe before continuing work.

c+xs
l The work area should be made as flat as

possible. If the work area is flat, operation
is made much easier and this reduces
operator fatigue.
The machine should always be operated at

a speed where it can be correctly con-
trolled. Never do the following:
0 Speeding
0 Sudden starting, sudden braking, sudden
turning.
0 Snaking
0 Coasting
Be careful of those around you, and al-

ways confirm that there is no person or
obstacle in the way before traveling or
turning the machine.
Always operate slowly in crowded places.
On haul roads or in narrow places, give
way to loaded vehicles.
- 1-7-
SAFElY HINTS. . . A
When traveling the machine, keep the

blade and ripper 40 to 50 cm above the
ground.
Do not let the machine pass the stop line.
Stop with sufficient margin.
Do not allow unauthorized persons into the

work area.
Do not use except for the intended pur-
pose.
Do not carry out any work that this ma-
chine is not intended for.
Always be aware of the operating capacity

of the machine. Using the machine to do
work beyond its capacity will not only
damage the machine, but may even cause
unexpected accidents.
Be careful of unbalanced loads. When car-
rying out side-cutting work or work where
there is a load on one side of the blade,
the rear of the machine may slip to the
GE.9
side.
0 The machine condition can be judged from

many factors. Changes in the gauges,
sound, vibration, exhaust gas color or re-
sponse of the control levers can indicate
the occurrence of some disorder. If any
disorder occurs, park the machine immedi-
ately in a safe place and take appropriate
action. Be especially careful in the case of
a fuel leak as there is danger of fire. ^__..
I --AX
- 1-8-
SAFETY HINTS. . . A
If the machine breaks down and needs to

be towed, first confirm that the brakes are
working properly, and then tow, using a
wire rope or any other suitable towing
equipment.
When parking the machine after discontinu-
ing work, put the gear shift lever into
“NEUTRAL”, apply the brake lock, lower the
blade and ripper to the ground, and put all
safety levers into the “LOCK” position.
Never leave the operator’s seat without
switching the engine off.
When continuing operations after rain, re-
member that conditions will have changed
from those before the rain started, so pro-
ceed with caution.
Be particularly careful when approaching
the shoulder .of the road or cliffs, as they
may have been loosened by the rain.
I G335a7
Check the load limits of bridges before

crossing.
After earthquakes, confirm that the ground
is still firm; after blasting, confirm that I
there are no unexploded charges
remaining.
When operating. on uneven ground or in
places where there are obstacles, remem-
ber the following points:
0 When operating on uneven ground,
travel at as low a speed as possible and
avoid sudden changes in direction. I . s-ax.36
0 Wherever possible, avoid traveling over

large rocks, fallen trees, tree stumps and
other such obstacles. Either use the
working equipment to remove them, or
travel round them.
When it ‘is impossible to avoid traveling
over them, put the gear shift lever into
a low speed, reduce speed and mount
over the obstacle. Just before the front
of the machine tips down, reduce speed
even more to make the shock of hitting
ground as small as possible.,
-l-9-
SAFETY HINTS. . . A
0 Never mount over an obstacle at an

angle; never disengage one steering
clutch to travel over an obstacle.
0 When operating at the edge of a cliff or on

the shoulder of a road, remember the fol-
lowing points:
0 When operating in a place where there
is danger of the machine falling over the
side, be doubly’ careful. Do not approach
the edge of the cliff or road shoulder by
mistake.
0 At the instant when the soil is dumped

over the cliff, or when the machine
passes the summit of a slope, the ma-
chine speed suddenly increases. This is
dangerous, so press the decelerator
pedal or use the fuel control lever to re-
duce the speed.
0 When dumping soil over a cliff, dump

the first excavated soil without dumping
it over, and use each succeeding exca-
vated soil to push the previous exca-
vated soil over. Be sure not to approach
the edge by mistake.
- l-10 -
SAFETY HINTS. . . A
0 When working on river embankments or

other places made of piled soil, there is
the danger that the weight or vibration
of the machine may cause the machine
to sink into the piled soil, so be ex-
tremely careful when operating in such
places.
When operating on slopes, remember the

following points:
0 When traveling on a slope, always travel
directly up or down it. Never travel hori-
zontally or diagonally across the slope,
as this may cause the machine to roll
over or slip sideways.
0 When going down a slope, use the en-

gine as a brake. If this is not enough to
control the speed of the machine, use
the steering brake as well.
Never coast down a slope with the gear
shift lever in “NEUTRAL”.
0 As far as possible, avoid turning the ma-

chine on a slope. It may cause the ma-
chine to roll over or slip sideways.
I Gal97
- 1-11 -
SAFETY HINTS. . . A
In forest areas, do not mount fallen

tree.s or logs. Piles of leaves or branches
are also very slippery, so proceed with
caution.
Before going up or down a slope, select
a travel speed most suited to the slope.
Do not change gear on the slope.
If the engine stalls on a slope, first use
the brake, lower the work equipment
and apply the parking brake to stop the
machine, then return the gear shift lever
to “NEUTRAL” before starting the engine
again.
l On downhill slopes, the steering is in the
opposite direction.
When traveling downhill under its own .
weight, the .machine may steer to the op-
posite side, so be careful when steering.
l When operating in water or in muddy

areas, remember the following points:
0 When operating in water or when cross-
ing shallows,, first check the bed soil
condition and the depth and flow speed
of water, then proceed, taking care not
to go beyond the permitted depth.
I GawQ
0 If the machine gets stuck in mud, it is

completely useless to increase the en-
gine speed, causing the tracks to spin,
or to rock the machine backwards and
forwards. In such a case, raise the blade
to reduce the load, and drive out slowly.
- l-12 -
SAFETY HINTS. . . A
l Be careful of buried objects (water pipes, gas

pipes, etc).
If it is thought that there are any buried objects,
contact the company in charge. Always identify
the location of buried objects before starting
work, and operate carefully.
0 When passing through a narrow space, be
careful of the side and overhead clearances.
Take special care not to touch any obstacles on
either side or overhead. If necessary, have
someone outside the machine call out
instructions.
l Be careful of the overall height.
Be careful when traveling through tunnels
or under bridges or electrical wiring, or
when entering storage areas, or other
places where there is a height limit.
0 Even proximity to the power line may re-
sult in electrical shock. Before starting
work, consult with the electric power
company.
l When operating at night, remember the fol-

lowing points:
0 Be sure to arrange an adequate lighting
system.
o At night it is very easy to make mis-

takes in assuming the distance and
height of objects and land.
- l-13 -
SAFETY HINTS. . . A
l When operating in fog, mist or smoke,

where visibility is bad, be especially careful
to confirm first whether operation is safe.
When visibility drops below safety level,
‘stop work and wait for the visibility to im-
prove.
l When operating in snow, or cleaning snow,

remember the following points:
0 Even slight slopes can cause unexpected
side slipping, so in such places, operate
with extreme caution.
0 Be careful when operating near road
shoulders or other structures.
When clearing snow on roads, the road
shoulder or other structures may be bu-
ried in snow and it may not be possible -
to see them, so operate carefully.
0 When traveling on icy roads or roads
covered with snow, slow down, and
avoid sudden starting or stopping, or
sudden operation of the steering.
0 Never use the steering brake to stop
suddenly on slopes. Lowering the work-
ing equipment is a far more effective
way of stopping.
0 The load may vary greatly according to
the quality of the snow, so adjust the
load and be careful not to slip.
l During operation, use the seat belt.
- 1-14 -
SAFETY HINTS. . . A
PARKING
When parking the machine, park it in a I
safe place outside the working area, or in
the specified place.
The following factors should be considered
when choosing a parking place: it should
be on flat, firm ground where there is no
danger of rockfalls, land-slides or floods. If
the machine has to be parked on a slope,
it should be parked facing directly up or
down the slope, and chocks should be
placed under the tracks. When the machine
is facing downhill, lower the blade so that
it cuts slightly into the ground to further
increase the safety.
When parking on a road, make sure the
machine can be clearly recognized by other
vehicles.
Provide flags, temporary barricades, illumi-
nation or other caution notices so that the
machine does not obstruct passage of
other vehicles and pedestrians.
When parking the machine, return the gear
shift lever to “NEUTRAL”, apply the brake
lock, lower the blade and ripper to the
ground, and put all safety levers in the
“LOCK” position. Switch off the engine and
remove the key.
- 1-15 -
SAFETY HINTS. . . A
MAINTENANCE
GENERAL
Wear well-fitting helmet, safety shoes and
‘working clothes. When drilling, grinding or
hammering, always wear protective goggles.
Wear proper clothes.
Do not let your clothes get caught on a pro-
truding part of the machine.
Do not wear oily clothes since they are likely ’
to catch fire.
Fuel or oil are dangerous substances.

Never handle fuel, oil, grease or oily
clothes in places where there is any fire of
flame.
As preparation in case of fire, always know
the location and directions for use of fire
extinguishers and other fire-fighting
equipment.
When working with others, choose a group

leader and work according to his instruc- niF%
tions. Do not perform any maintenance be-
yond the agreed work.
l *Do not handle electrical equipment while

wearing wet gloves, or in wet places, as
this can cause electric shock.
l During maintenance do not allow any
unauthorized person to stand near the
machine.
- l-16 -
SAFETY HINTS. . . A
Exhaust gas is dangerous. When working

inside, be particularly careful to have good
ventilation.
Clearances at the work equipment mounts
vary depending on the movement of the
work equipment. Be careful not to let any-
thing get between the clearances.
Unless you have special instructions to the

contrary, maintenance should always be
carried out with the engine stopped. If
maintenance is carried out with the engine
running, there must be two men present:
one sitting in the operator’s seat and the
other one performing the maintenance. In
such a case, never touch any moving part.
Always stop the engine before washing the
machine or charging oil.
When adding oil or fuel, do not let the oil
or fuel overflow.
Do not check the fan belt tension and
water pump while the engine is running.
Be sure to turn off the engine before in-
specting other rotating parts and the vi-
cinity thereof.
Always remember that the hydraulic oil cir-

cuit is under pressure. When feeding or
draining the oil or carrying out inspection
and maintenance, release the pressure first.
The procedure for releasing the hydraulic
pressure is as follows: lower the blade and
ripper to the ground, and stop the engine;
move the control levers to each position
two or three times and then slowly loosen
the oil filler cap.
- 1-17 -
SAFETY HINTS. . . A
DURING MAINTENANCE
0 Park the machine on firm, flat ground.
Lower the blade and ripper to the ground
and stop the engine. Return the gear shift I
lever to “NEUTRAL”, apply the brake lock

and set each control lever to “LOCK”.
When maintenance has to be carried out
with the blade and ripper raised, they must
be securely supported by blocks.
0 Hang a caution sign in the operator’s com-

partment (for example “Do not start” or
“Maintenance in progress”).
This will prevent anyone from starting or
moving the machine by mistake.
I sx59P
Flames should never be used instead of

lamps. Never use a naked flame to check
leaks or the level of oil, fuel, antifreeze or
electrolyte.
Immediately remove any oil or grease on
the floor of the operator’s compartment, or
on the handrail. It is very dangerous if
someone slips while on the machine.
GCOSPj
Be particularly careful when removing the

radiator cap or the hydraulic oil tank filler
cap. If this is done immediately after using
the machine, there is a danger that boiling
water or oil may spurt out.
- 1-18 -
SAFETY HINTS. . . A
l When adding oil or fuel, do not let the oil

or fuel overflow.
If oil or water are spilled, always wipe it
up. Spilled oil or water may cause people
to slip; spilled oil may cause fire.
If soil is piled on top of a place where fuel
has been spilled, remove the soil.
0 Remove all mud and dirt on the steering
clutch case which reach high temperatures.
l When the tracks are removed, never put
your fingers between the shoes.
l When handling the cutting edges, always III

wear gloves.
0 Remove the minus terminal from the bat-
tery in maintaining the electrical system.
l Lock the inspection cover.
When carrying out maintenance with the
inspection cover open, lock it securely with
the lock bar.
l Do not let attachments fall over.
When removing or installing any attach- 1
ment, place the attachment in a stable con-

dition and be careful not to let it fall over.
0 When carrying out other difficult mainten-
ance works, carrying them out carelessly
can cause unexpected accidents. If you
consider the maintenance is too difficult, al-
ways request your Komatsu distributor to
carry out it.
- 1-19 -
SAFElY HINTS : . . A
METHOD FOR GETTING ON 06 OFF THE

MACHINE
When getting on or off the machine, use
the handrails or steps.
When getting on or off the machine, al-
ways face the machine, use the handrails
and steps, and grip the handrails with both
hands.
Do not jump on or off. .

It is dangerous to get on or off the ma-
chine when it is traveling, or to jump on or
off the machine.
l Do not carry things when getting on or off

the machine.
It is dangerous to get on or off the ma-
chine when holding tools in your hand.
Pass objects by hand or use a rope to
raise them after getting on or off the
machine.
- l-20 -
SAFETY HINTS. . . A
POSITION FOR STICKING CAUTION AND NAME

PLATES
Always keep these plates clean. If they are
lost or damage, stick them back again or re-
place them with a new plate.
* There are other plates in addition to the
caution plates fisted as follows, so handle
them in the same way.
@JQ
W@ View from Y View from X
..
View from W
lT View from 2
c,j;;;
SAFE-R HINTS. . . A
1. Cautions before operating machine 4. Warnings for adjusting track tension
THROUGH LUBRICATOR
2 TO SLACKEN Il. RELEASE GREASE BY ROTATING
LUBRICATOR ONE TURN (FOR TRACK ADJUST
TEMNT PROCEDURE, READ OPERATION AND
MAINTENANCE MANUAL )
3. DO NOT LOOSEN LUBRICATCXZ MORE THAN ONE
FULL TURN ALSO BECAREFUL NOT TO LOOSEN
ANY OTHER PARTS TtiAN LUBRICATOR SINCE
THE GREASE IS UNDER HIGH PRESSURE EXCESS
LOOSENING IS HIGHLY DANGEROUS
1 AFTER ADJUSTING TM TRACK TENSION SECURELY
TIGHTEN THE LUBRICATOR AND INSTALL THE COVER
COVER , LuaRICATc4
2. Cautions for opening cap of 5. Cautions for preventing machine fire
1. ALWAYS STOP ENGINE WHEN CHECK REGULARLY ENGINE AND AREAS

REMOVING CAP. LIABLE TO BE A SOURCE OF FIRE.
REMOVE ACCUMULATED INFLAMMABLES
2. DO NOT LOOSEN CAP WHEN
SUCH AS LEAVES. TWIGS. ETC.
OIL TEMPERATURE IS HIGH. THESE MAY OBSTRUCT CONTROL AND
IF LOOSENED, CAUSE FIRE.
OIL MAY GUSH OUT.
3. SLOWLY OPEN HYDRAULIC
OIL TANK CAP AND RELEASE
INTERNAL PRESSURE
COMPLETELY,
4. DO NOT OPEN DRAIN PLUG
WHEN OIL TEMPERATURE
IS HIGH.
\
3. Warnings for starting engine and 6. Cautions for checking engine room
parking machine
OBSERVE THE FOLLOWING CAUTIONS WHEN

STARTING THE MACHINE OR WHEN YOU
WHILE ENGINE IS RUNNING:
LEAVE OPERATOR’S SEAT AFTER PARKING
THE MACHINE: 1. DO NOT OPEN COVER.
1. SET THE GEARSHIFT LEVER INTO NEUTRAL
POSITION AND LOCK IT WITH THE SAFETY
2. KEEP AWAY FROM FAN AND
LEVER WHEN APPLICABLE. FAN-BELT.
2. LOCK THE BRAKES.
3. LOWER THE WORKING EQUIPMENT TO THE
GROUND AND LOCK THE LEVER.
- l-22 -
SAFETY HINTS . . . A
7. Warnings for opening the radiator 10. Cautions for traveling on a slope
cap
I.
CAUTION
- PRECAUIDNS FOR ON.TIltCRUX O?ERATM(
- CWCK PROPRR AOJUSYMRNT OF SYRERNC IRAKES
- Flu UC FULLY FUEL TANK.

. KEE? YOUR FEET FRER FROM SlEPP*y. ON DECEl.ERATOR
NOT LOOSEN CAP WHEN PEDALS DURHG UC-GRADE YRAvELffi.

DO
17Nauuo.
WATER TEMPERATURE IS HIGH.
IF LOOSENED, BOILING WATER
MAY GUSH OUT BECAUSE OF
HIGH INTERNAL PRESSURE.
09660-03000
8. Cautions for inspection and 11. Cautions for fastening seat belt
maintenance
CAUTION
WHEN OPERATING MACHINE.
ALWAYSUSE SEAT BELT
WHEN CARRYING OUT ALWAYS CHECK CONDITION OF THE SEAT BELT.
MAINTENANCE, THE CONNECTING BRACKETS AND THE TIGHTING
1. PARK THE MACHINE ON LEVEL
BOLTS.
GROUND.
EQUIPMENT TO ADJUST SEAT TO ALLOW FULL BRAKE PEDAL TRAVEL
1. LOWER WORK
THE GROUND, AND LOCK WITH OPERATOR'S BACK AGAINST SEAT BACK.
THE LEVER. AFTER ADJUSTING THE HEIGHT. FORE AN0 AFT
3. DO NOT GO UNDER MACHINE POSITIONSOF THE SEAT,TIGHTEN THE TETHER BELT
WHEN IT IS RAISED BY THE BEFORE SITTINGIN THE SEAT.
WORK EQUIPMENT.
,o9173-o3ooo
9. Cautions for removing cab 12. Cautions for APS (Automatic .

Priming System)
CAUTION
IN CASE PREHEAT INDICATOR LAMP DOESN’T
LIGHT!
PREHEAT INDICATOR LAMP DOESN’T LIGHT ABOVE
-. _.
13-C 155.4’FI OF WATER TEMPERATURE. EVEN IF AT-
WHEN REMOVING OR INSTALLING THE MOSPHERI~ TEMPERATURE IS BELOW 15-c 69-F).
IN THIS CASE. ENGINE CAN START WITHOUT ‘APS’.
CAB, DISCONNECT THE FOLLOWING. FUtkTlON OF ‘APS’ IS CHECKED BY PREHEAT INDI-
(1) AIR CONDITIONER CONTROL CABLE CATOR LAMP. TURNING START SWITCH TO ‘HEAT’.
IF ENGINE STARTING IS DIFFICULT. TURN START
(2) CAB POWER SOURCE CONNECTOR SWITCH TO -HEAT- AND HOLD IT UNTIL PREHEAT
(3) WINDOW WASHER HOSE INDICATOR LAMP GOES OFF.
THEN QUICKLY TURN START SWITCH TO -START-.
NEVER USE APS WITH THE ETHER STARTING AID,
EXPLOSION MAY OCCUR.
17M-98-21710 -
6128-82-4990 I
- 1-23 -
MEMO
- 1-24 -
OPERATION
OPERATION
GENERAL LOCATIONS AND SPECIFICATIONS ................................ 2- 2
INSTRUMENTS AND CONTROLS ............................................ 2- 3
OPERATING YOUR MACHINE ................................................ 2-34
CHECKS BEFORE OPERATING THE MACHINE ............................. 2-34
BEFORE STARTING THE ENGINE .......................................... 2-37
TO START THE ENGINE .................................................. 2-39
AFTER STARTING ........................................................ 2-45
TO MOVE THE MACHINE OFF ............................................. 2-47
GEAR SHIFTING .......................................................... 2-50
FORWARD-REVERSE SHIFTING ........................................... 2-51
TURNING ................................................................ 2-53
TO STOP THE MACHINE ...................................... ............ 2-56
TO STOP THE ENGINE .................................................... 2-58
PRECAUTIONS FOR MACHINE OPERATlON .................................. 2-59
- 2-l -
GENERAL LOCATIONS AND SPECIFICATIONS
GENERAL LOCATIONS AND SPECIFICATIONS
1.. Blade 5. Sprocket

2. Blade lift cylinder 6. Track frame
3. Fuel tank 7. Blade frame
4. Ripper 8. Track shoe
OPERATING WEIGHT
(with semi U-blade, variable multi ripper, 610 mm
width track shoes, ROPS cab and air conditioner) 50000 kg
PERFORMANCE
Travel speed
Forward Max. 11.8 km/h
Reverse Max. 14.9 km/h
ENGINE
Model Komatsu S6D170 diesel engine
Flywheel horsepower (at 1800 rpm) 404 HP
NOTE: Specifications are subject to change without notice.
- 2-2 -
INSTRUMENTS AND CONTROLS

The role, action, and operation of devices
needed for operation are as follows.
MONITOR PANEL, LAMPS, SWITCHES, LE-

VERS AND PEDALS, OPERATOR’S SEAT,
SEAT BELT, FUSE BOX, DOOR LOCK, DUST
INDICATOR, LOCKING CAP
Knowledge of these devices is necessary
for safe and pleasant operation. Make sure
that you understand them thoroughly.
For details of the order of operation when
starting the machine, see OPERATING YOUR
MACHINE.
MONITOR PANEL
This monitor system consists of monitor lamp
groups (@, @I, G), meter group @J and switch
group 0.
@CHECK MONITOR GROUP

(Check items before starting)
If there is any abnormality, the appropriate
monitor lamp will flash.
Check the location where the monitor lamp
is flashing, and carry out the checks before
starting.
* When the engine is started, these monitor
lamps will go off even if there are abnor-
malities.
A 0 E GQ33K
- 2-3 -
@CAUTION MONITOR GROUP
(Caution items)
If the abnormality occurs while the engine
is, running, the appropriate monitor lamp and
the warning lamp will flash to indicate the ab-
normality.
* Even if the monitor lamp flashes, the ma-
chine can operate, but it should be re-
paired as soon as possible.
@CAUTION MONITOR GROUP

(Emergency caution items)
If any abnormality occurs while the engine
is running, the appropriate monitor lamp will
flash and the alarm buzzer will sound inter-
mittently at the same time.
* If any monitor lamp flashes, stop the work,
and repair it immediately.
@METER GROUP
This group consists of engine water tem-
perature gauge, power train oil temperature
gauge, fuel gauge, engine preheater monitor
and service meter.
@SWITCH GROUP
This group consists of starting switch, lamp
switches and preheater switch.
Functional check of the machine

monitor system
When the starting switch is turned ON be-
fore starting the engine, the monitor lamps
lights for 3 seconds, the warning lamp lights
for 2 seconds, and the alarm buzzer sounds
for 1 second. If any monitor lamp does not
light up, there is probably a broken bulb or
disconnection in the monitor, so ask your
Komatsu distributor to inspect it.
* The monitor system cannot be checked for
breakage until 30 seconds after the engine
has been stopped.
- 2-4 -
ASHECK MONITOR GROUP

(Check items before starting)
* When carrying out checks before starting,
do not simply rely on the monitor. Always
refer to the periodic maintenance items to
carry out the checks.
1. RADIATOR COOLANT LEVEL MONITOR

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

This monitor indicates a low oil level in the
engine oil pan.
If the monitor lamp flashes, check the oil
level in the engine oil pan and add oil as re-
quired. .
* Park the machine on level ground and
check the monitor lamps.
II GM311
B: CAUTION MONlTOR,GROUP
(Caution items)
* If the monitor lamp flashes, it should be
repaired as soon as possible.
1. CHARGE MONITOR
This monitor indicates an abnormality in the
charging system while the engine is running.
If the monitor lamp flashes, check the
charging circuit. I
f Park the machine on level ground and
* This monitor lamp lights, when’ the starting
switch is turned to ON immediately after
the engine is started or immediately before
the engine is stopped. It does not indicate
an abnormality.
j
D GX3.1
- 2-6 -
C: CAUTION MONITOR GROUP

(Emergency caution items)
* If any monitor lamp flashes, stop the en-
gine or run it at a low idling speed, and
repair it immediately.
1. ENGINE OIL PRESSURE MONITOR I

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

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

MONITOR
This monitor indicates a rise in the cooling
water temperature.
When the monitor lamp flashes, run the i
engine at the low idling speed until the green
range of the engine water temperature gauge
lights.
* Park the machine on level ground and
* Confirm that these monitor lamps light for
about 3 seconds after the starting switch is
turned to ON. If any monitor lamp does
not light, ask your Komatsu distributor to
inspect it.
- 2-7 -
4. POWER TRAIN OIL TEMPERATURE

MONITOR
This monitor indicates a rise in the oil tem-
perature of the torque converter outlet.
When the monitor lamp flashes, run the
engine at the low idling speed until the green
range of the power train oil temperature
gauge lights.
+ Park the machine on level ground and
* Confirm that these monitor lamps light for
about 3 seconds after the starting switch is
turned to ON. If any monitor lamp does
not light, ask your Komatsu distributor to
inspect it.
5. HYDRAULlC TEMPERATURE MONITOR

This monitor indicates a rise .in the hy-
draulic temperature.
When the monitor lamp flashes, stop the
machine and run the engine at the low idling
speed until oil temperature falls.
- 2-8 -
D:METER GROUP
t While the engine is at rest, turn the start-
ing switch ON to see if meter. lamps (l),
(2) and (3), and the monitor lamp all come
on. If they do not light, ask your Komatsu
distributor to inspect them.
1. ENGINE COOLING WATER TEMPERATURE [Ii

GAUGE
Red
Ttiis gauge indicates the temperature of
the cooling water. If the temperature is nor-
mal during operation, the green range will Green
light.
If the red range lights up during operation,
White
move the fuel control lever to lower the en-
gine speed to approx. 3/4 of the full speed,
F71Qb
and run until the water temperature enters 1
the green range.
If the engine cooling water temperature en-
ters the red range, and the engine water tem-
perature monitor flashes and the alarm buzzer
sounds, stop the machine and run at low id-
ling until the water temperature enters the
green range.
* If the water temperature gauge. often en-
ters the red range, check the radiator for
clogging.
- 2-9 -
2. POWER TRAIN OIL TEMPERATURE GAUGE

This gauge indicates the oil temperature of Red ~
the torque converter outlet. If the temperature
is normal during operation, the green range
will light.
If the red range lights up during operation,
move the fuel control lever to lower the en-
gine speed to approx. 3/4 of the full speed, Green
reduce the load and run until the oil tempera-

ture enters the green range.
If the power train oil temperature enters
the red range, and the power train oil tem-
perature monitor flashes and the alarm buzzer
sounds, stop the machine and run at low id-
ling until the oil temperature enters the green
range.
* If the power train oil temperature gauge
often enters the red range, we recommend
you to lower the travel speed one range
(for example, F2 - Fl) to reduce the load
on the power train when operating.
D GOC311
3. FUEL GAUGE
This gauge indicates the amount of fuel in
the fuel tank. If there is enough fuel in the
tank while the engine is running, the green
range lights. If the red range lights, there is
less than 130 liters of fuel in the tank.
When the red range lights, add fuel.
* The display is not directly proportional with
the remaining amount of fuel.
4. SERVICE METER
This meter shows the total operation hours
of the machine. The service meter advances
while the engine is running - even if the ma-
chine is not traveling.
Refer to the section “SERVICE METER”.
* While engine is running, green pilot lamp
on the service meter flashes to show the
service meter advances.
5. ENGINE PREHEATER MONITOR LAMP

This lamp indicates the engine preheating
time when starting the engine by operating
APS (Automatic Priming System) in the cold
weather. When the preheater switch is placed
in ON, this lamp lights and goes out after ap-
prox. 80 seconds, indicating that the preheat-
ing of the engine has been completed.
- 2-l 1 -
E: SWITCHES
1. STARTING SWITCH
This switch is used to start the engine.
OFF
Key insertion-withdrawal position. None of
electrical circuits activate.
ON
Charging and electric device circuits acti-
vate. Keep key at ON after starting.
START
At this key position, the starting motor will
crank the engine. Release key immediately
after starting.
HEAT
Glow plugs are preheated but APS (Auto-
matic Priming System) is not actuated.
l To operate switches (2) through (6) press

the surface lightly.
When the red lamp is lighted up, the
switch is ON; when the lamp is out, the
switch is OFF.
Press the switch lightly with your fingertip
to switch it ON, and press it again to
switch it OFF.
- 2-12 -
2. HEAD LAMP SWITCH

This switches on the head lamps and the
panel lamp.
* When the head lamp switch is on, green
lamps on switches (2), (3), (4), (5) and (6)
also come on.
3. REAR LAMP SWITCH I

This switches on the rear lamp and the
panel lamp.
* When- the rear lamp switch is on, green
also come on.
pi‘,, [
4. WORK LAMP SWITCH

This switches on the work lamps in front
of the L.H. and R.H. fenders and the panel
lamp.
1-c
* When this work lamp switch is on, green
also come on.
5. PREHEATER SWITCH
This switch is used to start the engine by
means of APS (Automatic Priming System).
When the switch is turned ON, the current
flows to the glow plugs, warming up the in-
3 El
take air. At this time, the preheater monitor
lamp on the monitor panel lights.
* Do not push this switch on when APS is
not in use.
* For further details, see “STARTING THE EN-
7 r
GINE IN COLD WEATHER”. Fasm
L
- 2-13 -
6. LOCKUP SWITCH
When this switch is ON (red lamp lighted
up), the lockup function of the torque conver- J L___-J
ter is actuated. When the lockup function is 7 / \
I 0
I
actuated, torque converter drive and direct
0J
drive are automatically selected according to
the load condition of the machine. When the
-J I 0
switch is OFF (red lamp OFF), only torque
converter drive is used.
* If the starting switch is moved to OFF

when any of switches (2) through (6) is on,
all switches (2) through (6) will go OFF.
Then, if the starting switch is moved to
ON, switches (2) through (6) will remain
OFF.
- 2-14 -
LAMPS
1. WARNING LAMP
When the monitor lamps of @ and G caution
groups in the machine monitor system flash,
II
this warning lamp flashes at the same time.
When the warning lamp flashes, confirm the
location of the abnormality on the monitor CAUTION LOCK UP
panel.
When the monitor lamp in 0 caution group
FW35~
is flashing, the alarm buzzer sounds intermit- I
tently.
* When the alarm buzzer sounds, immediately
stop work. Then, inspect and repair the faulty
part.
2. TORQUE CONVERTER LOCKUP PILOT

LAMP
When the lockup switch on the monitor
lamp panel is turned ON, and the torque con-
verter lockup is automatically actuated
(switched to direct drive), this lamp lights up.
When the transmission is torque converter
drive, the lamp goes OFF.
- 2-15 -
SWITCHES
1. HORN SWITCH
When this switch is pressed, the horn will
sound.
2. ROOM LAMP SWITCH

When this switch is moved to the ON posi-
tion, the room lamp will light.
- 2-16 -
3. WIPER SWITCHES
These switches are used to actuate the fol-
lowing wipers.
(1) Rear window wiper
(2) Door (R.H.) wiper
(3) Door (L.H.) wiper
(4) Front window wiper
Each switch can also be used to actuate a

window washer. Thus, each switch can be
used for the following three purposes.
0 Window washing only
0 Wiping only
l Wiping and washing
- 2-77 -
LEVERS AND PEDALS
1. FUEL CONTROL LEVER

This lever is used to control the engine
speed and output.
(l)Engine stop position:
Push the lever fully.
(2)Low idling position:
Pull the lever from engine stop position (1)
until you feel the operating force falls off.
(3) Full speed position:
Pull the lever fully from low idling position
(2).
2. STEERING LEVER
This lever is used to steer the machine.
To turn the machine gently to one direc-’
tion, pull the steering lever on the same side
halfway.
When the steering lever is further pulled all
the way out, the machine will make a sharp
pivot turn.
- 2-18 -
lN$TRUhiENTS AND CONTROLS
3. GEAR SHIFT LEVER

This lever is used to select the speed
range.
Three-speed forward and three-speed
reverse travel can easily be selected by sim-
ply shifting the gear shift lever to any desired
speed position.
+ Place the gear shift lever in the neutral po-
sition before starting the engine.
4. SAFETY LEVER (For gear shift tever)
A When the machine

be sure to set the
is stopped for a while,
gear shift lever in neu-
tral and set the safety lever to LOCK.
This is the locking device of the gear shift

lever.
- 2-19 -
5. BRAKE LOCK LEVER
A Whenever the machine is parked,

brake pedal without fail.
lock the
This device is used to lock the brake pedal

when parking.
Depress the brake pedal, both when apply-
ing the lock and when releasing the lock.
6-l BLAdE CONTROL LEVER

This device is used to operate the blade.
(1) RAISE ( bt_ 1
(2) HOLD ( b )
The blade remains stopped and held
position.
(3) LOWER ( bt )
(4) FLOAT ( & )
The blade can move freely according to
external force.
* When the lever is released while in posi-
tion (4), it does not spring back to HOLD
position. Move it back to the HOLD posi-
tion by hand.
RAISE
1
LOWER
(A) RIGHT TILT ( & )

(6) LEFT TILT (. J,& )
* The blade can be tilted at any position of
(1) to (3).
* The lever should be returned quickly to
HOLD position at the end of tilt cylinder
stroke.
* Do not operate tilting when blade is at top
or bottom position.
1
- 2-21 -
6-2 BLADE CONTROL LEVER

(For machines with dual tilt and pitch
mechanism)
This device is used to operate the blade.
(1) RAISE ( bt )
(2) HOLD ( b )
The blade remains stopped and held
position.
(3) LOWER ( & )
(4) FLOAT ( & )
The blade can move freely according to
external force.
* When the lever is released while in posi-
tion (4), it does not spring back to HOLD L
position. Move it back to the HOLD posi-

tion by hand.
(A) RIGHT DUAL TILT ( %- )

(B) LEFT DUAL TILT ( 4&! )
* The dual tilt can be operated at any posi-
tion from (1) to (3).
* If the dual tilt button is not pressed, the
normal tilt operation is carried out.
- 2-22 -
(C) PITCH DUMP ( ‘bL_ 1

* The most suitable cutting angle for digging
and rolling soil can be selected freely ac-
cording to the type of soil and shape of
the ground. This can be also used when
dumping the load.
(D) PITCH BACK ( z )
* The most suitable cutting angle for digging
and rolling soil can be selected freely ac-
cording to the type of soil and shape of
the ground.
* The pitch operation can be carried out at
any position from (1) to (3).
Ir Keep the button pressed and operate the

lever to the left or right, and the actuation
of the dual tilt and pitch will start.
* The pitch circuit is the priority circuit, so if
two buttons are pressed at the same time,
the pitch will be actuated.
- 2-23 -
7. SAFETY LOCK (For blade control lever)
A When parking or
be sure to lower
servicing the machine,
the blade and set the
safety lock in LOCK position.
This device is used to lock the blade con-

trol lever.
8. RIPPER CONTROL LEVER

This device is used to operate the ripper.
(1) RAISE ( 3 t )
(2) HOLD ( 3 )
The ripper remains stopped and held
position.
(3) LOWER ( 31 )
- 2-24 -
(A) Digging angle decrease ( 3, )

The digging angle (cc)decreases.
(B) Digging angle increase ( q# )
The digging angle (a) increases.
Digging a?gle Digzg angle

decrease increase im
9. SAFETY LOCK (For ripper control lever)
A When parking or servicing

be sure to lower the ripper
the machine,
and set’ safety
lock in LOCK position.
This device is used to lock the ripper con-

trol lever. \ !
10. PIN-PULLER CONTROL SWITCH

(If a giant ripper is installed)
Operate the pin-puller as follows.
(1) Pull out: pin is pulled out.
(2) Push in: pin is pushed in.
- 2-25 -
11. BRAKE PEDAL
A Do not place your foot on pedal unnec-

essarily.
When the brake pedal is depressed, both

left and right brakes are actuated.
12. DECELERATOR PEDAL
A when
When arriving at the top of a slope, or
dumping earth from a cliff, the ma-
chine will increase its speed with the sud-
den loss of load. Slow the machine by de-
pressing the decelerator pedal.
This pedal is used to reduce the engine

speed set by the fuel control lever.
When the pedal is depressed, the engine
speed is reduced.
- 2-26 -
OPERATOR’S SEAT
Set operator’s seat as follows for maxi-
mum comfort.
@ ADJUSTING DIRECTION OF SEAT

If handle (1) is pulled up, the seat can be
rotated 15” to right by hand. After changing
the direction of the seat, lower and lock the
handle securely.
@ HEIGHT ADJUSTMENT
To lower seat, turn knob (2) clockwise; to
raise, turn counterclockwise.
The adjustable amount is 50 mm.
0 FORWARD AND BACKWARD

ADJUSTMENT
Set the seat in the desired position by
moving lever (3) to left; then release the
lever.
The seat can be adjusted forwards or back-
ward 160 mm (in 8 steps).
@ ADJUSTING SEAT ACCORDING TO

OPERATOR’S WEIGHT
To obtain the best riding condition, turn
knob (4) clockwise for a light operator or turn
counterclockwise for a heavy operator.
g TILTING ADJUSTMENT
Set the backrest in the desired position by
pulling lever (5) upward, then release the
lever.
- 2-27 -
SEAT BELT
When operating a machine equipped with
ROPS, be sure to use the seat belt.
A securing
Before fastening the seat belt, inspect the
brackets and belt for abnormal
conditions.
A tether
Check that
belt.
there are no kinks in the
Fasten the belt and remove it in the follow-

/ -.
ing manner. \ \
1. Adjust the seat so that the brake pedal can
ator’s back .against the backrest.
2. After positioning the seat, adjust the tether
belt (1). With the seat unoccupied, tense. <&@
the belt slightly across the seat and install.
r
3. Sit in the seat. Hold buckle (2) with your
“\G/” Fpp3
left hand and tongue (3) with your right
hand, put the tongue into the buckle.
Check that the belt has locked by pulling it.
4. When removing the belt, raise the tip of
the buckle lever to release it.
* Fasten belt along your body without kink-
ing it. Adjust, the lengths of the belt on
both the buckle and the tonque sides so
that the buckle is located at the mid-point
of your body front.
- 2-28 -
Adjust the belt length in the following

manner.
1. To shorten the belt, pull the free end of k
the belt on either the buckle body or ton-
que side.
2. To lengthen, pull the belt while holding it

at a right angle to buckle or tonque.
* inspect bolts and fittings. on the chassis for
tightness. Retighten any loose .bolts to 2 to
3 kgm torque.
* If the seat is scratched or frayed or if any
of the fittings are broken or deformed from
long service, replace the seat belt
immediately.
- 2-29 -
FUSE BOX
A off
Before replacing a fuse,
the starting switch.
be sure to turn
The fuses protect the electrical equipment and

wiring from burning out.
If the fuse becomes corroded, or white powder
can be seen, or the fuse is loose in the fuse holder,
replace the fuse.
* Replace a fuse with another of the same
capacity.
Fuse arrangement and circuit

0 Fuse box I
Fuse
No. Circuit
capacity
0 20A Starting switch
f-3 Car stereo, Cigarette lighter,

5 20A
Room lamp
20A Wiper
@ 1OA -
3 10A Night lighting
20A Spare (Additional lamp)
s 10A Lockup switch
3 10A Panel lamp
10A Back-up alarm
20A Engine preheating
ct 10A Work lamp
a 20A Rear lamp
!j 20A Head lamp
10A Monitor, Horn, Pin-puller switch
- 2-30 -
l Fuse box II
Circuit
0 10A Front window wiper
@ 10A Rear window wiper

h II
0 10A Door wiper (L-H.)
0 10A Door wiper (R.H.)
@ 10A Room lamp
0 10A Cigarette lighter
@ 10A Car stereo
CONNECTOR FOR ADDITIONAL LAMP

This connector is secured with tape to the
connector divider for the pin-puller switch.
* Do not connect to any connector other
than this connector.
* Keep the current to a maximum of 20A for
the additional lamp.
- 2-31 -
DOOR LOCK
This lock is used to lock the door in posi-
tion when it is opened.
1. When the door is forced against catcher
(l), the door will be locked in position.
2. To release the door, push knob (2) above
the catcher. The catcher will’ unlock the
door.
* When locking the door in position, be sure
to force it firmly against the catcher.
DUST INDICATOR
This device indicates clogging of the air
cleaner element. When red piston (1) appears
in the, transparent part of this indicator, the
element is clogged. Immediately clean the
element.
After cleaning, push indicator button (2) to
return the red piston to the original position.
The dust indicator is on the air cleaner
bracket in the engine room.
- 2-32 -
A locking cap is available as an optional

radiator cap, fuel tank cap, power train oil
pan cap or hydraulic tank cap. Open and
close locking caps as follows:
To open the cap

1. Insert the key into the cap.
* Insert the key as far as it will go. If the Shoulder
key is turned before it is inserted all the
way, it may break. FOlao4
2. Turn the key counterclockwise and bring

the rotor groove in line with the aligning
mark on the cap. Turn the cap slowly until
a “clicking” sound is made. This releases
the lock and allows the cap to be opened.
Aligning
mark
To lock the cap
1. Turn the cap into place.
2. Turn the key clockwise and take the key
/ F?l405
out. -L
* When the cap is locked (against vandal-

ism), it rotates freely.
- 2-33 -
OPERATING YOUR MACHINE

The following is an explanation of the
checks before starting, method of starting the
engine, and controls for the machine needed
to operate the machine. Please read this sec-
tion carefully to acquire basic knowledge of
methods of operation.
CHECKS BEFORE OPERATING THE

MACHINE
Always carry out the following checks to
ensure safety for the operator and the main-
tenance of the machine performance.
CHECKS BEFORE STARTING (WALK-AROUND

CHECK)
Before starting the engine, check around
and under the machine to check the work
equipment and hydraulic system for any loose
nuts or bolts, or leakage of oil, -fuel, or
coolant.
Check also for any loose electric wires,
play, and collection of dirt around places that
reach high temperatures.
- 2-34 -
1. Check electric wires

Check if fuses are broken, and check for
any traces of disconnections or short circuits
in the electric wiring.
Check also for any loose terminals, and
tighten if necessary.
In particular, check the wiring of the
following:
0 Battery
0 Starting motor
l Alternator
l Engine ground wire
2. Check radiator for water leaks and

clogging.
3. Check around the engine for water and oil

leaks.
4. Check power train oil pan for oil leaks.
5. Check final drive case for oil leaks.
6. Check tightness of track roller support

mounting bolts and nuts.
7. Check for oil leaks at high pressure hose

joints and hydraulic cylinder.
8. Check monitor systeni

Check that all the monitor lamps light up
for 3 seconds, the warning lamp lights up for
2 seconds and the alarm buzzer sounds for 1
second.
9. Check coolant level, add water

Check the coolant level.
The coolant level must be above the bot-
tom of the strainer at the water filler port.
10. Check fuel level, add fuel

Check the fuel level with the dipstick.
- 2-35 -
11. Check oil level in engine oil pan, add oil
Check the engine oil level.
The oil level must be between the H and L
marks on the level gauge.
12. Check oil level in power train oil pan,

(Incl. transmission, torque converter and
bevel gear cases), add oil
Check the power train oil level.
The oil level must be between the H and L
marks on the level gauge (5 minutes after
starting the engine).
13. Check oil level in damper case, add oil

Check the damper oil level. The oil level
must be between the H and L marks on the
level gauge.
14. Check brake pedal travel

The pedal travel must be 100 it 5 mm.
15. Check dust indicator

Check that the red piston of the dust indi-
cator has not reached the service level.
* For details, refer to CHECK BEFORE

STARTING in MAINTENANCE section.
- 2-36 -
BEFORE STARTING THE ENGINE
A sitions
Before starting the engine, check
of all levers and pedals.
the po-
A cloth
Before starting the engine, use a damp
to wipe off the dust accumulated on
the top surface of the battery or on the
starting motor and the alternator.
I Fll89
A the
If the control lever is touched by accident,
dump body may move suddenly. When
leaving the operator’s compartment, al-
ways set the safety lock securely to the
LOCK position.
1. Adjust the seat so that brake pedal (1) can

ator’s back against the backrest.
2. is the brake pedal locked with brake lock

lever (Z)?
3. Is gear shift lever (4) in N (neutral) position

and locked with safety lever (3)?
* If the gear shift lever is not at the neutral
position, the starting motor will not turn
even when the starting switch is turned to
the START position.
- 2-37 -
4. Are the blade and the ripper lowered on

the ground?
And are safety locks (5) for blade control
lever and ripper control lever in the LOCK
positions?
5. Is fuel control lever (6) in the engine stop

position?
- 2-38 -
TO START THE ENGINE
A area,
Confirm the safety of the
then start the engine.
surrounding
I FI1.55
NORMAL STARTING
1. Turn the key of starting switch (1) to the
START position and run the engine about
10 seconds.
2. Then return the key of starting switch (1)

to the OFF position.
3. Pull fuel control lever (2) to the low idling

position.
- 2-39 -
4. Turn the key of starting switch (1) to the I
START position.
FG43
5. When engine is started, release the key of

starting switch (1) and the key will return
automatically to ON.
Do not leave the .key in START for more
than 20 seconds.
If engine will not start, repeat the starting
procedure after about 2 minutes.
The operation in Step 1 is aimed at lubri-
cating ail parts and extending the life of
m244
the machine. It also increases the combus-
tion pressure when a starting aid (Auto-
matic priming system) is used.
- 2-40 -
STARTING THE ENGINE IN COLD WEATHER

(starting with APS (Automatic Priming
System))
If the temperature becomes low, start the
engine as follows.
* When the action in Step 5 is taken while
the temperature of the engine cooling
water exceeds ZO”C, the preheater monitor
lamp will not light. In this case, start the
engine through the normal starting routine.
1. Open fuel valve (1) for the APS.

START position and run the engine about
10 seconds.
3. Then return the key of startin< switch (2)

to the OFF position..
- 2-41 -
4. Pull fuel control lever (3) a little toward I1

you from the low idling position.

ON position.
6. When preheater switch (4) is put in the ON

position, the switch red lamp and pre-
heater monitor lamp (5) come on. (Preheat-
ing will starts automatically)
7. Keep in this condition until preheater moni-
tor lamp (5) goes out. (Preheating is com-
pleted after approx. 80 seconds, and the
lamp goes out.)
8. When preheater monitor lamp (5) goes off,

turn the starting switch key to the START
position and start the engine.
- 2-42 -
9. Release the key of starting switch (2), and

the key will return automatically to ON.
10. When the engine runs smoothly and the
color of exhaust gas becomes normal, put
preheater switch (4) in the OFF position.
* The red lamp on preheater switch goes
Off.
* The time which should elapse before turn-

ing the preheater switch off varies with the
ambient temperature. Confirm the time to
the table below:
Time from the starting of

Ambient
engine until turning off the
temperature
preheater switch
15--c 1 - 2 minutes
Below O’C 3 - 5 minutes
* When the air temperature is below 15’C,

leave the valve open.
* If Step 6 to 8 are carried out without per-
forming Step 1, it may shorten the nozzle
life. Be sure to carry out Step 1.
* If the engine does not start through the
steps specified above-, return the fuel con-
trol lever to the engine stop position and
repeat Steps 2 to 8 at an interval of ap-
prox. 2 minutes.
* If the switch is moved to START while the
preheater monitor lamp is on in Step 8,
glow plugs will get wet, making firing im-
possible. This will make it difficult to start
the engine.
-2-43-
SPECIAL STARTING
When starting after running out of fuel, fill
with fuel, then fill the fuel filter cartridge with
clean fuel and bleed the air from the fuel sys-
tem before starting.
* For details of bleeding the air, see the sec-
tion on replacement of the FUEL FILTER.
-2-44-
AFTER STARTING
After starting the engine, do not immedi-
ately start operations. First, carry out the fol-
lowing operations and checks.
1. Run the engine at low idling speeds and 2

make sure engine oil pressure monitor
lamp (1) goes off.
2. Pull fuel control lever (2) and run the en-

gine at a medium speed. Then run the en-
gine at no load for about 5 minutes.
3. After warm-up run is completed; check
gauges, monitor lamps for proper oper-
ation.
* Continue to run the engine at light load
until the green range of the engine water
temperature gauge lights.
4. Check if the exhaust color is normal or
whether there is any abnormal noise or
vibration.
* Avoid abruptly accelerating the engine until
the completion of warm-up.
* Do not run the engine at low idling or high
idling for more than 20 minutes. If it is
necessary to run the engine at idling, apply
a load from time to time or raise the en-
gine speed to a medium speed.
- 2-45 -
* If the engine oil pressure monitor lamp

starts flashing and the buzzer starts sounds
intermittently, immediately stop the engine
and check for the cause of trouble.
* Check oil level in the power train oil pan.
(For the checking procedure, see CHECK
BEFORE STARTING.)
- 2-46 -
TO MOVE THE MACHINE OFF I - -
A safety
Before starting the machine, confirm the
around the machine, and make a
signal. CD
A slope,
If the machine has to be started on a
always unlock brake lock lever (4)
0
and depress brake pedal (3) continuously.
A When starting machine on a steep uphill

grade, run engine at full-throttle and shift
gear shift lever into 1st with brake pedal
depressed. As soon as the machine has
started slowly (or track shoes are slip-
ping), propel the machine by slowly re-
leasing brake pedal.
1. Unlock the blade control lever and the rip-

per control lever with safety locks (1).
Free
2. Put blade control lever (2) and ripper con-

trol lever (2) in the RAISE positions to raise
the blade and the ripper 40 to 50 cm off
the ground.
-2-47-
3. Depress brake pedal (3), place brake lock

lever .(4) in FREE, and return the brake
pedal to home position.
4. Unlock the gear’ shift lever with safety

lever (5).
5. Depress decelerator pedal (6) to decrease

engine speed so the machine can start off
without jerking.
6. Shift gear shift lever (7) in a desired posi-

tion and start the machine.
7. Pull fuel control lever (8) to increase en-

gine speed.
* If you are depressing the brake pedal, re-
lease the brake pedal slowly at the same Full speed
time.
- 2-49 -
GEAR SHIFTING
Gears can be shifted into any position by
gear shift lever (1).
* There is no need to stop the machine to
shift gears.
- 2-50 -
FORWARD-REVERSE SHIFTING
A When switching
REVERSE, check
between FORWARD and
first that the direction of
travel is safe.
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 en-
gine running at full speed, and always de-
press the decelerator pedal to lower the
engine speed.
1. Lower the engine speed by depressing

decelerator pedal (1).
2. Shift gear shift lever (2) to the desired

position.
- 2-51 -
1
3. increase engine speed by releasing deceler-
ator pedal (1).
* When the gear shift lever is placed in
REVERSE, the REVERSE warning buzzer will
sound.
- 2-52 -
TURNING
A Avoid as much as possible turning

machine on a slope. The machine
the
will
tend to slip sideways. Particular care
should be taken on soft or clay land.
Never turn when traveling at high speed.
To make a turn while traveling, pull steer-

ing lever (1) on the side in which you would
like to turn.
To make a gradual left turn

Pull the L.H. steering lever halfway (to the ‘------A
+ : _____‘?’ (
3r=
detent). The steering clutch will be disen-
gaged, allowing the machine to make a grad-
ual left turn.
* To make a gradual right turn, manipulate
the R.H. steering lever in the same manner
as described above.
- 2-53 -
To make a pivot left turn

Pull the L.H. steering lever all the way
backward. The steering clutch will be disen-
gaged and the steering brake will be applied.
* To make a pivot right turn, manipulate the
R.H. steering lever in the same manner as
described above.
- 2-54 -
TURNING WHILE DESCENDING A SLOPE I

When descending such a sharp slope that
the machine will go down of its own weight
or when going down a slope with a scraper
or the like, you should exercise. great care.
The machine will turn to the opposite side to
that of the pulled lever.
To make a gradual left turn

Pull the R.H. steering lever halfway to its
stroke end. The machine will make a gradual
left turn (compensation steering).
* To make a gradual right turn, manipulate
the L.H. steering lever in the same manner
as described above.
To make a pivot left turn

Pull the L.H. steering lever all the way
backward. Then, the machine will make a
pivot left turn (no compensation steering).
*. To make a pivot right turn, manipulate the
R.H. steering lever in the same manner as
described above.
- 2-55 -
OPERATlrjlG YOUR MACHINE
TO STOP THE MACHINE
A Always
ground.
stop the niachine on fiat, stable
Avoid parking in a dangerous
place.
Avoid stopping suddenly. Give yourself

ample room when stopping.
1. Lower engine speed by operating fuel con-

trol lever (1).
2. Place gear shift lever (2) in N (neutral) po-

sition.
3. Depress brake pedal (3) to stop the ma-

chine and lock the brakes with brake lock
lever (4).
- 2-56 -
4. Lock gear shift lever (2) with safety lever

(5).
Free a
Lock 6
5. Put blade control lever (6) and ripper con-

trol lever (6) in the LOWER positions to
lower blade and ripper to the ground.
6. Lock blade control lever (6) and ripper con-

trol lever (6) with safety locks (7).
- 2-57 -
TO STOP THE ENGINE

Cool ,the engine gradually before stopping
the engine.
1. Cool the engine by running it at low idling
speed for about 5 minutes.
2. Push fuel control lever (1) in the engine I

stop position and stop the engine. Engine stop
3. Return the key of starting switch (2) to OFF

and remove the key.
* If the engine is stopped abruptly before it
cools down, engine life may be greatly
shortend.
Never stop the engine abruptly except in
case of emergency.
* Especially when the engine is overheated,
allow the engine to idle without immediate
stoppage so that the engine is gradually
cooled down to be ready for proper
stoppage.
- 2-58 -
PRECAUTIONS FOR MACHINE OPERATION

PRECAUTIONS DURING OPERATION
Pay attention to gauges

When the red range lights on the power
train oil temperature gauge while operating,
reduce load and wait for lowering of tem-
perature.
Method of using steering clutch

If the steering clutch one side is used fre-
quently 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.
Method of using brakes

The following actions cause premature
damage to the brakes, so avoid such oper-
ations.
0 Using emergency brake at full speed
0’ Using brake with engine running at full
speed in first gear (Fl, Rl) (Machine
stall condition)
* Always depress the decelerator pedal to
lower the engine speed before actuating
the brakes.
PERMISSIBLE WATER DEPTH

When operating in water, always keep the
top surface of the track frame above the sur-
face of the water.
- 2-59 -
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 re-
duced and the machine will stop. Further-
more, the engine sometimes will stall.
Use engine as a brake

When going downhill, shift gear shift lever
into low speed to run engine at slow speed
and travel down slope using the engine as a
brake.
When traveling down hills of more than
15”, shift down to 1st speed (Rl or Fl).
Further, do not use the torque converter
lockup.
Braking when traveling downhill

While descending a slope using the engine
as a brake, also apply the brakes immedi-
ately.
Failure to brake may result in overrunning,
causing engine trouble.
Use care, not to shift gears while descend-
ing down with a scraper (or the like)
mounted, for the engine tends to overrun.
- 2-60 -
PRECAUTIONS ON SLOPES
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 ma-
chine 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 ZO”, fill every place with oil to H
level.
Precautions when engine stops on slopes

If the engine stops while working or travel-
ing on a hill, immediately depress the brake
pedal to bring the machine to a complete
stop.
- 2-61 -
PRECAUTIONS WHEN OPERATING THE

WORK EQUIPMENT CONTROL LEVERS
0 When operating the blade tilt, ripper lift,

and ripper tilt, when the cylinder reaches
the end of its stroke, return the lever as
quickly as possible to the HOLD position,
or operate it in the opposite direction.
* If the circuit is relieved repeatedly over a
long time, it will cause overheating of the
hydraulic oil.
0 Do not operate the lever to the end of its

stroke, release it momentarily and then re-
lieve it again.
* If the circuit is relieved again with the cy-
linder at the end of its stroke, an abnormal
peak pressure will be generated in the hy-
draulic circuit, and this will cause damage
to the pumps and other equipment.
In particular, never do this when the hy-
draulic oil is at a low temperature.
- 2-62 -
MAINTENANCE
MAINTENANCE
PRECAUTIONS FOR MAINTENANCE ................................... ...... 3- 2
MAINTENANCE TABLE ...................................................... 3- 6
OIL FILLER AND LEVEL GAUGE POSITIONS .................................. 3-10
CHECK BEFORE STARTING ............................................... 3-11
EVERY 250 HOURS SERVICE .............................. ................ 3-17
EVERY 500 HOURS SERVICE .............................................. 3-26
EVERY 1000 HOURS SERVICE .................................... ......... 3-29
EVERY 2000 HOURS SERVICE ............................................. 3-34
EVERY 4000 HOURS SERVICE ............................................. 3-40
WHEN REQUIRED ........... ..................................... ........ 3-41
ADJUSTMENT .............................................................. 3-55
PERIODICAL REPLACEMENT OF SAFETY PARTS ............................. 3-60
- 3-l -
PRECAUTION FOR MAINTENANCE
PRECAUTION FOR MAINTENAN’CE

Always use Komatsu genuine parts for re-
placement.
Always use the grades of grease and oil
recommended by Komatsu. ,Choose the
viscosity specified for the ambient
temperature.
Always use pure oil or grease, and be sure
to use clean containers.
When checking or changing the oil, do it in
a place free of dust, and prevent any dirt
from getting into the oil.
Thoroughly wash the machine. In particular;
be careful to clean the filler caps, grease
fittings and the area around the dipsticks.
Be careful not to let any dirt or dust into
the system.
When check an open gear case there is a

risk of dropping things in. Before removing
the covers to inspect such cases, empty
everything from your pockets. Be particu-
larly careful to remove wrenches and nuts.
It is dangerous to drain oil or water or to
replace the filters immediately after stop-
ping the engine. Wait for the temperature
to go down before carrying out these oper-
ations. If the oil has to be drained when it
is cold, warm up the oil to a suitable tem-
perature (approx. 20 - 40°C) before drain-
ing it.
0 After replacing oil, filter element or
strainer, bleed the air from the circuit.
0 When the strainer is located in the oil filler,
the strainer must not be removed while
adding oil.
- 3-2 -
When adding oil or checking the oil level,

check that the oil is at the correct level.
After greasing up, always wipe off the old
grease that was forced out.
When changing the oil or filter, check the
drained oil and filter for any signs of ex-
cessive metal particles or other foreign
materials.
When removing parts containing O-rings,
gaskets or seals, clean the mounting sur- I Fx116Z
face and replace with new sealing parts.

Special measuring apparatus is needed for
testing hydraulic pressure.
When working on the sea shore, carefully
clean all electrical equipment to ensure that
is does not corrode.
Before working in muddy water, rain or
snow, check that the various plugs, valves,
are properly screwed up. Upon completion
of work, wash the machine, then check the
various parts of the machine for cracking,
scratching, loose or missing nuts and bolts.
Also, oil and grease the various parts of
the machine.
When working on rocky ground, be careful
of damage to the undercarriage, loose nuts
and bolts, cracks, wear and other damage.
When working in a dusty location, be care-
ful of the following:
1) Inspect the dust indicator to see whether
the air cleaner is blocked up. Clean the
air cleaner as soon as it becomes dirty.
2) Clean the radiator core so that it does
not become blocked up.
3) Clean or replace the fuel filter as soon
as it becomes dirty.
4) Clean the electrical equipment, particu-
larly the starting motor and alternator, to
prevent accumulation of dust.
- 3-3 -
0 Bleed air from hydraulic circuit. After re-

placing oil and filter element or cleaning
strainer, bleed the air from the circuit.
When changing the oil in the hydraulic
tank, or removing the hydraulic cylinder, or
removing the hydraulic piping, run the en-
gine at low idling and bleed the air in the
following way after assembling.
1) Operate each hydraulic cylinders 4 to 5
times, stopping 100 mm from stroke
end.
2) Next, operate each cylinder 3 to 4
times to the stroke end.
* If the engine is run at high speed at
first, or if the cylinder is moved to the
end of its stroke, the air in the cylinder
may damage the piston packing, etc.
0 Grease fittings are provided at rod ends
used in the lever linkage. These rod ends
are lubrication-free and require no greas-
ing. When they stop moving smoothly after
being in service for a long time, however,
add grease to them.
0 When washing the machine, take care not
to splash water over the electrical equip-
ment. If it is soaked with water, it may not
operate normally.
0 After disconnecting the connector, cover it
with a vinyl bag to prevent oil or dust
from sticking to its contact section.
0 When adding fuel, be careful not to allow
the water collected at the top or bottom of
the drum to get into the fuel.
0 Use ordinary automobile washer fluid. Be
careful not to let dirt or dust get in.
- 3-4 -
If the oil or cooling water have been

drained, put a warning sign in the oper-
ator’s compartment to prevent any other
person from starting the engine by mis-
take.
When welding, be careful of the following:
1) Turn OFF the power (starting switch).
2) Do not continuously apply more than
200 V.
3) Install the ground cable at least 1 m
from the range to be welded.
4) Take care not to install the seals be-
tween the grounded point and the
range to be welded.
Before installing a radio to the machine,
contact your Komatsu distributor. The ma-
chine monitor controller may make oper-
ation errors because of interference from
the external radio waves.
When carrying out other difficult mainten-
ance works, carrying them out carelessly
can cause unexpected accidents. If you
consider the maintenance is too difficult, al-
ways request the Komatsu distributor to
carry out it.
- 3-5 -
MAINTENANCE TABLE
MAINTENANCE TABLE
No. ITEM SERVICE PAGE
CHECK BEFORE STARTING

a Monitor system Check 3-11
b Coolant Check and supply
C Fuel Check and supply 3-l 2
d Engine oil pan Check and supply 3-l 3
Power train oil pan

e (incl. transmission, torque Check and supply 3-14
converter and bevel gear cases)
f Damper case . Check and supply . 3-14
9 Brake’pedal Check travel 3-l 5
h Dust indicator Check 3-l 5
i Electric wirings Check 3-l 5
j Engine ground Check
EVERY 250 HOURS SERVICE

(The items marked * are carried out after the first 250 hours only for new
machines.)
* Replace cartridge 3-17

Fuel filter
* Transmission oil filter and Replace elements 3-17
toraue converter oil filter
* Change oil and clean 3-l 7
Power train oil pan strainer
4 Final drive case Change oil 3-l 7
* kha;i;toil and replace 3-17
Hydraulic tank and filter
* Engine valve clearance Check and adjust 3-17
a Lubricating 3-l 7
-1 Blade lift cylinder suport yoke Lubricate 4 points 3-17
-2 Blade lift cylinder support shaft Lubricate 2 points 3-l 7
-3 Blade arm ball joint Lubricate 5 points 3-l 8
- 3-6 -
MAINTENANCE TABLE
No. ITEM SERVICE
-4 Brace screw Lubricate 2 points 3-18
-5 Ripper tilt cylinder bottom pin Lubricate 2 points 3-18
-6 Ripper lift cylinder bottom pin Lubricate 2 points 3-l 8
-7 Ripper tilt cylinder rod end pin Lubricate 2 points 3-l 8
-8 Ripper lift cylinder rod end pin Lubricate 2 points 3-18
-9 Ripper arm pin (Front) Lubricate 2 points 3-l 8
-10 Ripper arm pin (Rear) Lubricate 2 points 3-18
-11 Equalizer bar side shaft Lubricate 2 points 3-18
-12 Suspension Lubricate 5 points 3-19
-13 Fan pulley Lubricate 1 point 3-19
b Hydraulic tank Check and supply 3-20

Ft;;g,“,“il and replace 3-21
C Engine oil pan and filter
g
d Fuel filter Drain water and sediment 3-23
e Alternator drive belt Check tension 3-23
f Battery electrolyte Check level 3-24
g Brake performance Check 3-25

a Fuel filter Replace cartridge 3-26
Transmission oil filter and Replace elements 3-27
b
toraue converter oil filter
C Final drive case Check and supply 3-28

Change oil and clean 3-29
a Power train oil pan strainer
b Fuel strainer Clean
C Steering clutch case breather Clean 3-31
- 3-7 -
MAINTENANCE TABLE
No. ITEM SERVICE
(EVERY 1000 HOURS SERVIDE)
d Lubricating 3-31
-1 Tension pulley ass’y Lubricate 1 point 3-31
e Recoil spring case Check and supply
f Corrosion resistor Replace cartridge 3-32
9 Turbocharger mounting bolts Check and retighten 3-33

a Final drive case Change oil 3-34
Change oil and replace
b Hydraulic tank and filter 3-35
element
C Pivot bearing Check and supply 3-36
d Change oil and clean air 3-36

Damper case hole and breather
e Engine breather Clean 3-37
f Clean and rotating 3-38

Turbocharger condition
9 Turbocharger rotor Check play 3-39
h Engine valve clearance Check and adjust 3-39
i Alternator and starting motor Check 3-39

a Water pump Check 3-40
b Vibration damper Check 3-40
WHEN REQUIRED
a Track Check tension
b Track shoe bolt Check and retighten 3-42
C Radiator fin Clean 3-43
- 3-8 -
MAINTENANCE TABLE
No. ITEM SERVICE
d Fuel tank strainer Check and clean 3-44

Drain water and
e Fuel tank sediment 3-44
f End bits and cutting edges
Check, when atmospheric

g APS (Automatic Priming System) temperature drops 3-46
below 15°C
h Air conditioner air filter Clean 3-47
i Cooling system Clean 3-46
Check, clean or
i Air cleaner replace element 3-52
when required
- 3-9 -
OIL FILLER AND LEVEL GAUGE POSITIONS
OIL FILLER AND LEVEL GAUGE POSITIONS

Radiator cooling Engine oil pan
water inlft level gauge, oil filler
Power train oil \

Radiator cooying Engine oil ian Recoil spring
pan drain valve
water drain valve drain valve case oil filler
Hydraulic tank Hydraulic tank

Fuel tank
oil filler sight gauge
oil filler
Fuel Damper case
Final drive case Final-drive case Hydraulic tank

drain plug level plug, oil filler drain valve
z-“--i
< __
- 3-10 -
CHECK BEFORE STARTING.

a. CHECK MONITOR SYSTEM
1. Turn starting switch (1) to ON.
2. Check that all the monitor lamps, light for
3 seconds, the warning lamp lights for 2
seconds and the alarm buzzer sounds for 1
second.
* If any monitor lamp does not light up,
there is probably some failure or
disconnection, so contact your Komatsu
distributor.
* When carrying out checks before starting,
do not simply rely on the monitor.
Always make the check by referring to this
MAINTENANCE section.
b. CHECK AND REFILL COOLANT
A ing
Do not remove caps (1) and (2), while cool-
water is hot. Hot water may spout
out.
When removing caps (1) and (2), wait until
the water temperature goes down and re-
lease inner pressure little by little by
loosening caps slowly, then remove the
cap.
1. Remove radiator cap (1) and check that Radiator

coolant is above the bottom of the strainer
as shown in the diagram. If necessary, add
water.
- 3-11 -
2. If the water level is low, add water through .

Subtank
fillers of both radiator cap (1) and subtank
cap (2). Add into the subtank up to the
level above the bottom of the strainer
through filler of cap (2) as shown in the
diagram.
3. To refill the radiator, first stop the engine
and pour in _ water until the
water overflows the filler opening. Then,
start the engine, check the water level
again after a five-minute idling, and add
water if necessary.
* If more water than normal is required to
fill up to the specified level, coolant is con-
sidered to be leaking somewhere. Immedi-
ately locate the leak and plug it.
* When checking the coolant level in the
radiator, do not depend only on the radia-
tor coolant level monitor.
C. CHECK FUEL LEVEL
A When adding fuel, never let the fuel over-

flow. This may cause a fire.
1. After removing cap,. pull out fuel dipstick

(G) and check fuel level.
2. After each operation, fill up the fuel tank
through the filler.
* A clogged cap breather hole (1) may stop
the fuel flow to the engine.
Check it from time to time and clean.
* When dozing on a grade, make sure there
is plenty of oil in the tank so that the en-
gine fuel line does not become aerated.
* Fuel capacity: 840 Q
- 3-12 -
d. CHECK OIL LEVEL IN ENGINE’OIL PAN

1. Use dipstick (G) to check the oil level.
2. The oil level should be between mark L
and H. If necessary, add engine oil at oil
filler (F).
* The type of lubricant used depends on the
ambient temperature. Select according to
the table “FUEL, COOLANT AND LUBRI-
CANTS”. _
F119ZA
* The dipstick is marked with levels on each

side for ENGINE STOPPED and ENGINE ID- ENGINE STOPPED ENGINE IDLING
LING.
* When measuring the oil level with the en-
gine stopped, use the marks on the EN-
GINE STOPPED side.
It is also possible to check the oil level
with the engine idling, but be sure to re-
member the following points.
The engine water temperature must be 1
within the green range.
When the engine is idling, use the
marks on the ENGINE IDLING side.
Remove the oil filler cap.
* When checking the oil level with the
engine stopped, wait for at least 15
minutes after stopping the engine before
checking the level. _ If the oil level is
checked immediately after stopping the en-
gine, oil will remain in various parts, so it
will not be possible to obtain an accurate
measurement.
* While adding oil, take out the oil level
gauge through the gauge guide to bleed
the air from the crankcase.
* When checking the engine oil level, do not
depend only on the engine oil level
monitor.
- 3-13 -
e. CHECK OIL LEVEL IN POWER TRAIN OIL

PAN (INCL. TRANSMISSION, TORQUE
CONVERTER AND BEVEL GEAR CASES)
1. Start the engine, run for 5 minutes, then
measure the oil level using the COLD
marking on gauge (G) with the engine run-
ning at idling.
* When the engine is stopped, the oil level
rises, so it is impossible to check the oil
level accurately.
* When checking the oil level during or after
operation, measure the oil level using the
HOT marking on gauge (G) with the engine
running at idling.
* When operating on slopes of 20” or more,
check that the oil level is up to the H
mark.
2. If the oil level is low, add engine oil
through oil filler port (F).
the table, “FUEL, COOLANT AND LUBRI-
CANTS”.
f. CHECK OIL LEVEL IN DAMPER CASE

1. Use dipstick (G) to check the oil level with
the engine stopped.
2. The oil level should be between mark L
and H. If necessary, add engine oil through
the dipstick guide hole.
CANTS”.
- 3-14 -
g. CHECK BRAKE PEDAL TRAVEL

The pedal travel should be 100 f 5 mm
when the brake pedal is fully depressed.
h. CHECK DUST INDICATOR

When air cleaner element is clogged, the
red piston of dust indicator (1) reaches the
service level and gets locked.
In that case, clean the element referring to
the section “WHEN REQUIRED”.
After cleaning the element, push the button
to return the red piston.
i. CHECK ELECTRIC WIRINGS
A ofIf the fuse is damaged or there is any sign

shortcircuiting in the electric wiring, al-
ways investigate the cause and correct it.
Check for damage of the fuse and any sign

of disconnection or short circuit in the electric
wiring. Check also for loose terminals and
tighten any loosen parts.
Battery
Starting motor
Alternator
Please contact your Komatsu distributor for

investigation and correction of the cause.
- 3-15 -
i. CHECK ENGINE GROUND

1. Check that ground wire (1) has not come
off or broken, and that there is no damage
to the terminal portion.
If the ground wire comes off or there is
any other abnormality, replace it with a
new part.
2. Check that terminal mounting bolt (2) is
not loose. If any loose bolts are found,
tighten them.
* Tightening torque: 6 - 7.5 kgm
- 3-16 -

Carry out the following maintenance. only
after the first 250 hours.
0 FUEL FILTER, REPLACE CARTRIDGE
0 TRANSMISSION OIL FILTER AND TORQUE
CONVERTER OIL FILTER,
REPLACE ELEMENTS
0 POWER TRAIN OIL PAN (INCL. TRANS-
MISSION, TORQUE CONVERTER AND
BEVEL GEAR CASES), CHANGE OIL AND
CLEAN STRAINER
0 FINAL DRIVE CASE, CHANGE OIL
0 HYDRAULIC TANK AND. FILTER, CHANGE
OIL AND REPLACE ELEMENT
0 ENGINE VALVE CLEARANCE, CHECK AND
ADJUST
For details of the method of replacing or
maintaining, see the section on EVERY 500
HOURS, 1000 HOURS and 2000 HOURS
SERVICE.
a. LUBRICATING
Apply grease to the grease fittings shown
by arrows.
1. Blade lift cylinder support yoke (4 points)

2. Blade lift cylinder support shaft (2 points)
- 3-17 -
3. Blade arm ball joint (5 points)

4. Brace screw (2 points)
5. Ripper tilt cylinder bottom pin (2 points)

6. Ripper lift cylinder bottom pin (2 points)
7. Ripper tilt cylinder rod end pin (2 points)
8. Ripper lift cylinder rod end pin (2 points)
9. Ripper arm pin (Front) (2 points)
10. Ripper arm pin (Rear) (2 points)
* The ripper on the upper side is a multi-

shank ripper, and the one on the lower
side is a giant ripper.
11. Equalizer bar side shaft (2 points)

Remove mud or dust on the upper side 0
of the equalizer bar end.
Remove plug (1) to apply grease.
Be sure to fit plug (1) after lubricating.
Tightening torque: 34 f 4 kgm :2&E
il
j i /; // ! /
- j“
J 1 (1 ij I / i/
: -.x
- 3-18 -
12. Suspension (5 points)

Grease the suspension through the grease
fittings marked by arrow.
(1) - (4): Suspension rod pin
(5): Equalizer bar center shaft
Pump the greasing lever up and down 3
- 5 times.
13. Fan pulley (1 point)
- 3-19 -
b. HYDRAULIC TANK
A When oil temperature is high, do not

remove the cap. Hot oil sometimes spouts
out.
When removing the cap, wait until the oil
temperature goes down and turn it slowly
to relieve inner pressure.
1. Lower the blade to the ground in horizontal

position, lower the ripper shank vertically
and put the tip of the shank in contact
with the ground.
2. Stop engine, and, wait for about 5 minutes
before checking oil level. If oil level is not
between top and. bottom of red circle in
sight gauge (G), refill tank with engine oil
through oil filler (F).
* This inspection should be carried out be-
fore starting the engine.
CANTS”.
- 3-20 -
C. ENGINE OIL PAN AND FILTER

1. Remove the covers mounted under ma-
chine body.
Remove drain plug (1) and loosen drain
valve (2). Tighten drain valve (2) and plug
(1) after draining the oil.
2. Using a filter wrench, remove filter car-

tridge (3) by turning it counterclockwise.
* If filter cartridge (3) is removed immedi-
ately after stopping the engine, oil will
spill. Wait at least 10 minutes after stop-
ping the engine before replacing the filter
cartridge.
3. Clean the filter holder, fill a new cartridge
with engine oil and coat the seal and
thread of the cartridge with engine oil (a
thin coat of grease is also possible), then
install the cartridge.
* When installing, screw in until the packing
contacts the seal face of the filter holder,
then tighten 3/4 to 1 of a turn.
4. After replacing the cartridge, refill the spe-
cified quantity of engine oil through oil
filler (F).
- 3-21 -
EVERY 250 HQURS SERVICE
5. Idle the engine for a while, stop the engine

and check the oil level. For details, refer to
section CHECK BEFORE STARTING.
* Refill capacity: 51 Q
CANTS”.
t Tightening torque.
drain plug (1): 7fl kgm
drain valve (2): 6.5 f 1.5 kgm
* Use a genuine Komatsu filter cartridge.
* Change the engine oil and the filter car-
tridge every 6 months regardless of service
hours.
* Take care not to loosen drain valve (2) so
much that the stopper pin in the valve is
distorted.
- 3-22 -
d. FUEL FILTER
1. Loosen air bleeding plug (1) and remove
drain plug (2) on the bottom of the filter to
drain water and sediment accumulated on
the bottom of the fuel filter.
2. After draining, loosen the knob of feed
pump (3) and move the knob up and down
to bleed air. When no air bubbles come
out of the air bleeding plug hole, tighten
the plug and the knob.
e. ALTERNATOR DRIVE BELT

1. The belt tension should normally deflect by
approx. 15 mm when pressed with the
finger at a point midway between the alter-
nator pulley and the drive pulley (approx.
5 kg).
Alternator pulley
Drive pulley
- 3-23 -
2. To adjust the belt tension, loosen bolts (l),

and nuts (2), rotate turnbuckle (3).
3. After adjustment, tighten nuts (2) and bolts -
(1) securely.
* Check each pulley for damage, and
V-grooves and V-belt for wear. Particularly,
check whether V-belt is in contact with bot-
tom of V-groove through wear.
* Replace belt if it has stretched, leaving no
allowance for adjustment, or if there is a
cut or crack on belt.
* When the belt is replaced, readjust its ten-
sion after running for an hour.
f. BATTERY ELECTROLYTE
A To avoid gas explosions, do not bring fire

or sparks near the battery.
A clothes,
if the electrolyte gets on your skin
immediately wash with plenty
or
of
clean water.
Remove caps (1) and check the electrolyte

level.
If the electrolyte level is lower than the
prescribed level (10 to 12 mm above the
plate), supply distilled water.
* Should any of the acid be spilt, have it re-
plenished by the nearest battery shop with
acid of the correct specific gravity.
* When inspecting electrolyte level, clean the
air hole of the battery cap.
- 3-24 -
g. BRAKE PERFORMANCE
A check
If the machine moves when the following
is carried out, ask your Komatsu
distributor to carry out repair.
A speed
Do not place the gear shift lever in the 1st
position. Otherwise, it will cause
damage to the machine.
Before starting the engine, confirm the

safety around the machine and carry out the
following check.
1. Start the engine.
2. Raise the work equipment. Keep the work
equipment control lever safety lock in
“FREE”.
3. Place the brake lock lever in “FREE”.
4. Depress the brake pedal and place the
gear shift lever in the 2nd speed position.
5. Increase the engine speed little, by little up
to full speed.
- 3-25 -

* Maintenance for every 250 hours should
be carried out at same time.
a. FUEL FILTER
1. Close valve (1).
2. Remove drain plug (P) on the bottom of

the filter to drain fuel.
3. Using a filter wrench, remove cartridge (2)
by turning it counterclockwise.
4. Clean the filter holder, fill a new cartridge
with clean fuel and refit it after applying a
dab of oil to the packing face.
* To refit the cartridge, place the packing
face in contact with the seal face of the fil-
ter holder, then screw up the cartridge l/2 -
to 3/4 of a turn.
5. After replacing cartridge (2), open valve (1)
and loosen air bleeding plug (3).
- 3-26 -
6. Loosen the knob of feed pump (4) and

move the pump up and down to draw off
fuel until air ceases to come out of plug
(3).
7. Tighten up air bleeding plug (3).
Push in the knob of feed pump (4) and
tighten it.
* Be sure to use a genuine Komatsu car-
tridge.
* After replacing the cartridge, start up the
engine and check the filter seal face for
possible oil leakage.
b. TRANSMISSION OIL FILTER AND TORQUE

CONVERTER OIL FILTER
1. Remove the cover on R.H. fender.
When bolts (1) are removed and cover (2)
is lifted up, the -elements and valve can be
taken out together with cover (2).
2. Remove bolts which are tightening the
valve. Take elements (3) out of the filter
cases. Clean the inside of the case and the
removed parts, and install new elements.
* Replace the O-ring at the same time.
* Be sure to use a genuine Komatsu ele-
ment.
- 3-27 -
c. FINAL DRIVE CASE

Remove level plug (G) and when it is
found that the oil is not filled nearly to the
lower edge of the plug hole, add engine oil
through plug hole (G).
CANTS”.
+ The maintenance should be made placing
the machine on a horizontal plane.
- 3-28 -

* Maintenance for every 250 and 500 hours
should be carried out at the same time.
a. POWER TRAIN OIL PAN

(INCL. TRANSMISSION, TORQUE CONVER-
TER AND BEVEL GEAR CASES)
1. Open the cover on the bottom of the body.
2. Take out hose (I), open drain valve (2) to

drain the oil.
After draining; tighten drain valve (2).
3. Put back hose (1) and install the cover.
4. Remove the inspection cover on L.H. fen-

der, and remove bolts (3) and cover (4).
- 3-29 -
5. Take out spring (5), strainer (6) and mag-

net (7).
6. Remove all dirt from the strainer, then
wash in clean diesel oil or flushing oil.
Clean the case interior and the removed
parts, then install them.
7. After replacing the transmission oil filter

and torque converter oil filter elements
(see “EVERY 500 HOURS SERVICE”), refill
the specified quantity of engine oil through
oil filler (F).
8. Check the oil level and ensure that is cor-
rect. (Refer to CHECK BEFORE STARTING.)
* Refill capacity: 120 Q
CANTS”.
* If any damage to spring (5), strainer (6) or
magnet (7) is found, replace with a new
part.
b. FUEL STRAINER
Tighten valve (l), remove cap (2), and take
out the strainer. Clean the strainer and the
strainer case. After installing it, open valve
(1).
* The strainer is soldered on cap (2).
- 3-30 -
c. .STEERING CLUTCH CASE BREATHER

1. Remove bolts (1) and cover (2).
2 Remove breather (3) on steering clutch

case, and wash out dust remaining inside
with clean diesel oil and flushing oil.
d. LUBRICATING
Apply grease to the grease fitting shown
by an arrow.
1. Tension pulley ass’ y (1 point)
- 3-31 -
e. RECOIL SPRING CASE

1. Remove bolts (l), then remove cover (2).
2. insert a scale and check that oil level is

160 - 180 mm from the upper face of in-
spection hole. If the level is low, add en-
gine oil.
* When removing the cover, take care not to
let mud or dust get in.
* Use CLASS CD SAE30 engine oil regardless
of the ambient temperature.
f. CORROSION RESISTOR
1. Close valve (1) on the upper side of the
corrosion resistor.
2. Using the filter wrench provided, remove
cartridge (2) by turning it counterclockwise.
Fit a new cartridge after applying a dab of
engine oil to the seal face.
* To fit the cartridge, put the seal face in
contact with head, then screw it up about
2/3 of a turn.
3. After replacement, open valve (1).
* Be sure to use a genuine Komatsu car-
tridge.
- 3-32 -
g. TURBOCHARGER MOUNTING BOLTS

Contact your Komatsu distributor for check-
ing, or proceed as follows:
Tighten if necessary.
a Turbine housing - center housing connec-
tion bolt
Tightening torque: 4.5 to 5.5 kgm
l Blower housing V clamp
Tightening torque: 0.8 to 1.O kgm
0 Exhaust manifold - turbine housing con-
nection bolt (For turbocharger mounting)
l Turbocharger oil feed pipe (inlet line)
nipple
Tightening torque:
M8 0.5 to 1.0 kgm
0 Turbocharger oil feed pipe (outlet line)
flange bolt
- 3-33 -

* Maintenance for every 250, 500 and 1000
hours should be carried out at the same
time.
a. FINAL DRIVE CASE

1. Remove drain plug (1) and drain the oil.
After draining, tighten drain plug (1).
2. Remove filler hole plug (Z), and refill the

engine oil until oil overflows from filler
hole (3).
After refilling the oil, tighten the plug.
CANTS”.
* Refill capacity: 43 Q for each side.
- 3-34 -
b. HYDRAULIC TANK AND FILTER

1. Remove drain plug (1) on the hydraulic
tank bottom and loosen drain valve (2) to
drain the oil. After draining, tighten plug (1)
and valve (2).
2. Remove bolts (3), lift up cover (4), and

take out element (6) and valve together
with the cover.
3. Remove nut (5) which is tightening element
(6) and clean the removed parts and filter
case interior. Install a new element.
* Replace O-ring at the same time.
4. After replacing the element, pour the speci-

fied quantity of engine oil through oil filler
(F).
5. Check the oil level and ensure that is
correct.
(Refer to EVERY 250 HOURS SERVICE.)
* Refill capacity: 95 !?
CANTS”.
* Use a genuine Komatsu element.
- 3-35 -
c. PIVOT BEARING
1. Remove plug (1).
2. Check that the oil level is up to the speci-

Oil level
fied level as shown in the diagram.
If the level is low, add the engine oil
through plug hole (1).
* Use CLASS CD SAE30 engine oil regardless’
of the ambient temperature.
d. DAMPER CASE
1. Open the inspection cover under the
chassis.
2. Remove dipstick (l), then remove drain
plug (2) and drain the oil. After draining
the oil, tighten the drain plug again.
3. Add engine oil through the dipstick guide
hole.
* Refill capacity: 2.1 J2
CANTS”.
4. Remove air hole plate (3) at four places
from the top of the damper cover, remove
any dirt or dust, then wash it in clean die-
sel oil or flushing oil.
If it is impossible to clean breather (4)
completely, replace it with a new part.
- 3-36 -
e. ENGINE BREATHER
1. Loosen clamp (l), then remove the hose.
2. Remove bolt (Z), then remove breather
body (3).
3. Rinse the whole body in diesel oil or flush-
ing oil.
4. After washing, pass clean diesel oil through

in the direction of the arrow.
5. After drying with compressed air, coat the
O-ring with engine oil, and install.
* Check the element and O-ring, and replace
with new parts if necessary.
6. Check the breather hose, and if there is
any oil sludge on the inside, replace it with
a new hose.
- 3-37 -
f. TURBOCHARGER
Ask Komatsu distributor to clean the turbo-
charger and check rotation of the rotor impel-
ler, or proceed as follows.
1. Remove the intake pipe connector and the
lubrication pipe from the turbocharger.
2. Remove the blower housing so that the
blower impeller can be seen.
3. When cleaning the blower impeller, do not
use a wire brush or other device which
may scratch the impeller. Clean it with light
oil. If it is very dirty, use a soft brush
made of animal hair.
4. Pour the light oil through the oil filter of
the turbocharger and rotate the impeller
several turns to wash out the sludge.
5. Rotate the impeller with your fingers as
high speed to check the rotation.
* If the impeller rotates at least one turn and
no sound of hitting comes from inside, it is
normal. If any abnormality is found, call
Komatsu distributor.
6. After cleaning and checking, blow off the
light oil with air and add engine oil.
- 3-38 -
g. TURBOCHARGER ROTOR
Ask Komatsu distributor to check the play
of the turbocharger rotor, or perform the fol-
lowing steps after cleaning and checking it.
0 Play in axial direction of rotor ass’y
Move the rotor ass’y in the direction of

the shaft. Measure the play in the direc-
tion of the shaft with a dial gauge.
Standard: 0.08 - 0.18 mm
0 Play in radial direction of rotor ass’y
Move the shaft end at the blower side
of the rotor ass’y in the radial direction
with your finger, and measure the play
with a dial gauge.
Standard: 0.25 - 0.60 mm
* If the play exceeds the allowable limit, ask
Komatsu distributor for repair or replace-
ment.
h. ENGINE VALVE CLEARANCE

As special tool is required for removing
and adjusting the parts, you shall request
Komatsu distributor for service.
i. ALTERNATOR AND STARTING MOTOR

The brush may be worn, or the bearing
may have run out of grease, so please con-
tact your Komatsu distributor for inspection or
repair.
* If the engine is started frequently, carry out
inspection every 1000 hours.
- 3-39 -

* Maintenance for every 250, 500, 1000 and
2000 hours should be carried out at the
same time.
a. WATER PUMP
Check that there is no play , oil leakage,
water leakage, or clogging of the drain hole.
If any abnormality is found, please contact
your Komatsu distributor for disassembly and
repair or replacement.
b. VIBRATION DAMPER
Check decrease of damper fluid, dent or
out-of-flat. If there is any abnormality, contact
Komatsu distributor for repair.
Since both works above-mentioned requires
special tools, contact your Komatsu distributor
for repair.
- 3-40 -
WHEN REQUIRED
WHEN REQUIRED
a. CHECK AND ADJUST TRACK TENSION
The wear of pins and bushings on the
undercarriage will vary with the working
conditions and soil properties. It is thus
necessary to continually inspect the track
tension so as to maintain the standard ten-
sion on it.
If the track tension is not at the standard
value, adjust it in the following manner:
Inspection
Stop the machine on level ground (stop
with the transmission in FORWARD without
applying the brake.) Then place a straight bar
on the track shoes between the carrier roller
and the idler as shown in the figure, and
measure the clearance between the bar and
the grouser at the midpoint. If the clearance
is 20 - 30 mm, the tension is standard.
Adjustment
A rotation.
Do not loosen plug (4) over one complete
Also, be careful not to loosen
any part other than plug (4).
If plug (4) or any other part should be
loosened excessively, it will be liable to
fly out under the high pressure of jammed
grease. If grease does not ooze smoothly,
try moving the machine back and forth for
a short distance.
1. Remove bolt (1) and remove cover (2).

* When removing cover (2), prevent any dirt
from getting into the hole.
2. For tightening the tension, pressurize
grease through grease fitting (3). On the
other hand, for loosening the tension, ex-
tract grease by reversely rotating plug (4)
for “1 rotation”.
- 3-41 -
3. Grease may be pressurized till S will be
370 mm. In case the tension is yet loose
after applying pressurized injection of
grease till the abovementioned limit, it indi-
cates that the pin bush is reduced by too
much abrasion. So it is necessary either to
turn or replace the pin and bushings. Con-
sult your Komatsu distributor for repair.
b. CHECK AND RETIGHTEN TRACK SHOE

BOLT
The shoe bolt attaching the track shoe to the
link will be broken if it is used as loosened. So,
you are required to. retighten every time you
find a loosened one.
Method for tightening (shoe bolt)
1. First tighten to a tightening torque of 70 + 7
kgm, then check that the nut and shoe are in
close contact with the link contact surface.
2. After checking, tighten a further 120” + lo’.
Method for tightening (master link connect-

ing bolt)
1. First tighten to a tightening torque of 50 f
5 kgm, then check that the link contact sur-
faces are in close contact.
2. After checking, tighten a further 180” + 10”.
Order for tightening

Tightening sequence is shown in the
diagram.
- 3-42 -
WHEN REQUIRED
c. CHECK AND CLEAN RADIATOR FIN

When the radiator fin block with mud, dirt
or leaves, clean it as follows.
1. Loosen the bolts and open radiator grille
(1).
2. Mud, dust, or leaves blocking the fin shall
be blown off by compressed air. Steam or
water may also be employed instead of
compressed air.
* Check the rubber hose on this occasion
and replace hose that is cracked or fragile.
Further, also inspect loosened hose clamps.
- 3-43 -
WHEN REQUIRED
d. CLEAN FUEL TANK STRAINER .

Clean the strainer if there is any dirt col-
lected in it.
Remove the filler cap of the fuel tank and
take out strainer (1).
If the strainer is dirty, clean it with diesel
fuel.
e. 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 bot-
tom together with mixed water and fuel.
-3-44-
WHEN REQUIRED
f. REPLACE THE END BITS AND CUTTING

EDGES
Turn or replace the end bits and cutting
edges when they have worn out to the wear
limit. Request Komatsu distributor for main-
tenance.
Loosen nut (1) and remove bolt (2). Then,

turn or replace the end bit or cutting edge.
* Install the edge to the blade, then tighten
partially. Drop the blade three to five times
on to the ground or rock to remove any
play in bolt (2), then tighten it to the cor-
rect tightening torque.
* If nut (1) and bolt (2) are damaged, replace
them with new ones at the same time.
* When installing end bit (3), put top surface

(4) of the end bit in close contact with
stopper (5), then tighten with the bolts.
* Tightening torque: 153 + 16 kgm
* After several hours of running, retighten
the nuts.
* When the nut is rusted and is removed by I Cut on both sides

gas cutting, cut on both sides of the nut as
shown in the diagram.
Be careful not to damage the seat surface.
If it is damaged, repair it. Be careful not to
get spatter on the mounting surface.
- 3-45 -
WHEN REQUIRED
g. CHECK APS (Automatic Priming .

System)
Check the APS in .autumn (ambient tem-
perature below 15”, engine cooling water tem-
perature below 13”).
1. Open fuel valve (1) of the APS and remove

hoses (2) of the nozzle inlet.
* If it is necessary to inspect the APS when
the engine cooling. water is above 13”C, ask
your Komatsu distributor to make the in-’
spection. .
2. Move feed pump (3) up and down to bleed
air until no air bubbles comes out of the
hose connecting port.
At the same time; check for fuel leakage
and clogging of fuel pipe.
3. Place the fuel control lever in the “engine
stop” position. Turn the starting switch to
ON position. Turn on the preheater switch.
Then, confirm the following.
Confirm that the preheater monitor lamp
stays on for about 80 seconds.
Confirm that when the preheater monitor
lamp goes off, the two glow plugs are
red hot.
With preheater monitor lamp off, turn
the starting switch key to START posi-
tion (do not keep the key in this position
for more than 20 seconds), and check
for proper fuel combustion inside the in-
take manifold.
* When checking the glow plug, remove
plug.
* If any abnormality is assumed, refer to the
“TROUBLE SHOOTING GUIDE”.
- 3-46 -
WHEN REQUIRED
h. CLEAN AIR CONDITIONER AIR FILTER

If the air conditioner air filter is clogged or
there is dirt or oil stuck to it, clean the filter.
1. Open the inspection cover, push up clip

(l), then remove fresh air filter (2).
2. Remove screw (3) at the left side of the .

operator’s seat, then remove internal filter @ I\\:
(4). _/-----~ $
3. Clean filters (2) and (4) with compressed L&
air. If any oil is stuck to the filter, or the
filter is extremely dirty, wash it in water
containing a neutral detergent. After wash-
ing it in water, dry the filter completely,
then install it again.
\/ io15771
* If the dirt clogging the filter cannot be
removed by blowing it with air or washing
it in water, replace the filter. with a new
part.
-3-47-
WHEN REQUIRED
i. CLEAN INSIDE OF COOLING ‘SYSTEM

Clean the inside of the cooling system,
change the coolant, and replace the corrosion
resistor, according to the table.
A Antifreeze is flammable,
from any flame.
so keep it away
A remove
If the water
the
temperature is high, do not
cap. This is because of the
possibility of scalding water spurting out.
When removing the cap, wait until the
water temperature goes down and turn
the cap slowly to allow pressure to be re-
lieved.
Stop the machine on level ground when

cleaning or changing the coolant.
Use a permanent type of antifreeze.
If, for some reason, it is impossible to use
permanent type antifreeze, use an anti-
freeze containing ethylene glycol.
Be sure to replace the corrosion resistor
cartridge.
Use city water for the cooling water.
If river water, well water or other such
water supply must be used, contact your
Komatsu distributor.
Cleaning inside of
Type of antifreeze Replacing corrosion
cooling system and
solution resistor
changing coolant
Every year (autumn) or

Permanent type antifreeze
every 2000 hours whichever
(All season type)
comes first
Non permanent type Every 6 months (spring, Every 1000 hours and when
antifreeze containing autumn) cleaning the inside of the
ethylene glycol (Drain antifreeze in spring, cooling system and when
(Winter, one season type) add antifreeze in autumn) changing coolant
Every 6 months or
When not using antifreeze every 1000 hours whichever
comes first
- 3-48 -
WHEN REQUIRED
Add antifreeze in the cooling water

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 tempera-
ture about 10°C lower when deciding the
mixing rate.
Mixing rate of water and antifreeze
Min.
atmospheric
temperature -5 -10 -15 -20 -25 -30
(‘Cl
Amount of
antifreeze 31 41 49 55 62 68
(Q)
Amount of
water 105 95 87 81 74 68
(Q)
* We recommend use of an antifreeze

density gauge to control the mixing
proportions.
-3-49-
WHEN REQUIRED
1. Stop the engine and close corrosion resis-

tor valve (1).
2. Turn radiator cap (2) slowly until it comes

Off.
3. Loosen drain valve (3) at the bottom of

radiator, drain valve (4) on the oil cooler
and drain valve (5) at the side of cylinder
block and drain off the cooling water.
4. Close up drain valves (3), (4) and (5) and
pour in clean water (ex. city water) up to
the vicinity of the water filler.
5. When the water reaches the vicinity of the
water filler, put the engine at low idling,
open drain valves (3), (4) and (5), then
pass water through the cooling system for
10 minutes.
* When doing this, keep the radiator filled up
to the filler with water.
6. After washing the cooling system, stop the
engine. Drain water and close drain valves
(3), (4) and (5).
- 3-50 -
WHEN REQUIRED
7. After draining off the cooling water, wash

out the cooling system using commer-
cially available detergent. Follow the in-
structibns on the detergent container.
8. After washing the cooling system, drain
off all the water, then close up drain
valves and pour in clean water (ex. city
water) slowly up to the vicinity of the
water filler.
9. When the water reaches the vicinity of
the water filler, put the engine at low id-
ling, open the drain valves, then pass
water through the cooling system until
clean water comes out from the drain
valves.
* When doing this, keep the radiator filled
up to the filler with water.
10. When the water becomes completely
clean, stop the engine and close all drain
valves.
11. Replace the corrosion resistor cartridge
and open valve (1).
.* For details of replacement of the corro-
sion resistor, see EVERY 1000 HOURS
SERVICE.
12. Supply water until it overflows from water
filler.
13. Run the engine for 5 minutes at low id-
ling and then for another 5 minutes at
high idling to eliminate air trapped in the
cooling system (leave radiator cap (2) off
during this operation).
14. Stop the engine and wait for about 3
minutes. Supply cooling water up to the
specified level. Tighten the cap.
15. Open the cap of subtank (6) and add
water into the subtank referring to the
section “CHECK BEFORE STARTING”.
- 3-51 -
WHEN REQUIRED
j. CHECK, CLEAN AND REPLACE AIR

CLEANER ELEMENT
A element
Do not clean or replace the air cleaner
with the engine running.
Checking
Whenever the red piston in dust indicator
(1) appears, clean the air cleaner outer ele-
ment.
Cleaning or replacing outer element

1. Loosen wing nut (2) and remove outer ele-
ment (3).
2. Clean the air cleaner body interior.
3. Clean and inspect the element. (See the
item “Cleaning outer element” for cleaning
procedure.)
4. Install the cleaned element.
5. Push the indicator button to return the red
piston to the original position.
* Replace the outer element which has been
cleaned 6 times repeatedly or used
throughout a year.
Replace the inner element at the same
time.
* Replace both inner and outer elements
when the dust indicator red piston appears
soon after installing the cleaned outer eie-
ment even though it has not been cleaned
6 times.
* Check inner element mounting nuts for
looseness and, if necessary, retighten.
* Replace seal washer (4) or wing nut (2) if
they are broken.
- 3-52 -
WHEN REQUIRED
Replacing inner element

1. First remove the outer element, and then
remove the inner element.
2. Cover the air outlet port (air connector
side) with a clean cloth or tape.
3. Clean the air cleaner body interior. Remove
the cover from the air outlet port.
4. Fit a new inner element to the connector
and tighten it with nuts.
5. Install the outer element, and push the in-
dicator button to return the red piston to
the original position.
* Do not attempt to reinstall a cleaned inner
element.
Cleaning outer element
A When using compressed

glasses and other things
air, wear safety
required to main-
tain safety.
With compressed air
Direct dry compressed air (less than 7 kg/

cm*) to element from inside along its folds,
then direct it from outside along its folds and
again from inside, and check element.
- 3-53 -
WHEN REQUIRED
* If small holes oi thinner parts are found on

element when it is checked with an electric
bulb after cleaning, replace the element.
* When cleaning element, do not hit it or
beat it against something. ,.-
::,21-
* Do not use element whose folds or gasket .r;-
9
or seal are damaged. r.
/
-.
I ’ ,-t,
- .. ’
::..S’ F,ma?
- 3-54 -
ADJUSTMENT
ADJUSTMENT
ADJUSTMENT OF DECELERATOR
PEDAL
Check
When the engine speed is not within the
range of 800 to 900 rpm by setting the fuel
control lever to l/2 stroke and depressing the
decelerator pedal (clearance (A); zero), the
following process shall be followed.
Adjustment
1. Use the fuel control lever to adjust the en-
gine speed to 800 - 900 rpm.
Next, remove inspection cover (l), loosen
locknut (2), and adjust turnbuckle (3) to set
clearance (A) to 0 mm.
2. Tighten locknut (2) after completing the ad-
justment.
* Tachometer is required for setting the en-
gine revolution with precision. So,. you
shall consult Komatsu distributor.
- 3-55 -
ADJUSTMENT
ADJUSTMENT OF FAN BELT

As this machine is provided with a device
which keeps a constant fan belt tension with-
out regard to elongation of the V-belt, no ad-
justment is required until the belt is broken.
Check the size (A) to see that it is main-
tained within 50 + 5 mm. If not, adjust the
fan belt.
* Replace three V-belts at the same time.
- 3-56 -
ADJUSTMENT
ADJUSTMENT OF IDLER CLEARANCE

Since the idlers are forced to move for-
ward and backward as long as the machine is
in operation, side guides (l), and guide plates
(2) will be worn out gradually.
Excessive wear of these guides and plates,
if left unattended, will cause the vibration of
idlers from side to side or inclination of the
idlers, and running off of track links from the
idlers or unevenly worn idler and links may
result.
Therefore, it is necessary to adjust the id-
lers from time to time according to the fol-
lowing procedure so that they are always
maintained in good running conditions.
Method for adjustment

1. Run the machine 1 or 2 meters on level
ground. to give its tracks even tension and
then stop the machine. Check the clearance
“A” between the track frames and side
guides (1) (there are a total of 4 clearan-
ces: left, right, inside and outside).
2. If the clearance “A” exceeds 3 mm,
remove bolts (3), and remove the required
number of shims (4) to adjust the clear-
ante to the value of 0.5 mm or below.
* The thickness of a shim is 0.5 or 1.0 mm.
- 3-57 -
ADJUSTMENT
ADJUSTING VOLUME OF BACKUP

ALARM
When the gear shift lever is placed in
reverse, the backup alarm will sound. When
carrying out work at night or in other places
where the volume of the alarm must be lo-
wered because of environmental problems,
the volume can be adjusted as follows.
(When the machine is shipped from the fac-
tory, the volume is set at the maximum H
level.)
Adjustment
1. Remove cover (1) at the rear of the right
fender.
2. Remove cover (2) of the backup alarm.
3. Change the position of the bridge to adjust

the volume.
0 The backup alarm volume can be adjusted
in three stages as shown in the table
below.
Connection Volume
0/a
Level Remarks
of bridge
I ! dB (A)
0 L-H I H 112
6 L-M M 107 Frequency:

1300 Hz
-,
C L-L L 97
* Set the volume of the backup alarm so

that it is at least 10 dB(A) higher than the
surrounding noise.
- 3-58 -
PERIODICAL REPLACEMENT OF SAFETY PARTS

To ensure safety at all times when operating or driving the machine, the
user of the machine must always carry out periodic maintenance. In addition,
to further improve safety, the user should also carry out periodic replacement
of the parts given in the table on the next page. These parts are particularly
closely connected to safety and fire prevention.
With these parts, the material changes as time passed, or they easily wear or
deteriorate. However, it is difficult to judge the condition of the parts simply by
periodic maintenance, so they should always be replaced after a fixed time has
passed, regardless of their condition. This is necessary to ensure that they al-
ways maintain their function compeletly.
However, if these parts show any abnormality before the replacement inter-
val has passed, they should be repaired or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking,
replace the clamps at the same as the hoses.
Carry out the following inspection for hydraulic hoses in addition to the peri-
odic replacement parts listed on the next page. If any abnormality is found,
tighten, replace, or take any other necessary action.
Category of inspection Inspection item
Check before starting Leakage from joints or caulked portion of fuel or hydraulic hoses
Periodic inspection Leakage from joints or caulked portion of fuel or hydraulic hoses
(monthly inspection) Damage (cracks, wear and tear) of fuel or hydraulic hoses
Periodic inspection Leakage from joints or caulked portion of fuel or hydraulic hoses
(yearly inspection) Interference, deterioration, twisting, damage (cracks, wear and
tear, crushed parts) of fuel or hydraulic hoses
- 3-60 -
+ When replacing the hoses, aiways replace the O-rings, gaskets, and other
such parts at the same time.
t Ask your Komatsu distributor to replace the safety parts.
No. Part name Unit Replacement intervals
0 Fuel spill hose (between nozzles) 5
@ Turbocharger lubricating hose 1
@I Fuel hose (Nozzle - fuel return hose) 1 Every 4000 hours or

every 2 years, whichever
comes sooner
0 Fuel hose for APS 3
@ Fuel hose (Fuel filter - injection pump) 3
@ Fuel hose (Feed pump - fuel return hose) 1
- 3-61 -
PERIODICAL PEPLACEMENT OF SAFETY PARTS
No. Part name Unit Replacement intervals
0 Hose (Torque converter oil cooler - steering case) 1
@ Hose (Blade valve - blade cylinder) 4
$ Inspection hose assembly for power train pressure 1
Every 4000 hours or

@ Fuel hose (Fuel tank - fuel strainer) 3 every 2 years, whichever
comes sooner
0 Fuel return hose 1
Hose (Torque converter outlet - torque converter 2

42
oil cooler)
D Fuel hose (Fuel strainer - feed pump) 1
- 3-62 -
OPERATING INSTRUMENTS
OPERATING INSTRUMENTS
BULLDOZER’S WORK ....................................................... 4- 2
EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER ................. 4- 4
EFFECTIVE METHOD OF OPERATION FOR RIPPER ............................ 4-l 1
TIPS FOR LONGER UNDERCARRIAGE LIFE ................................... 4-14
ADJUSTMENT OF WORK EQUIPMENT ....................................... 4-17
PROCEDURE FOR REMOVING AND INSTALLING CAB ......................... 4-21
OPERATING THE CAR STEREO .............................................. 4-26
OPERATING THE AIR CONDITIONER ......................................... 4-30
HANDLING OF BATTERY .................................................... 4-38
COLD WEATHER OPERATION ....................................... ........ 4-42
STORAGE .................................................................. 4-45
f This section gives details of the handling of standard equipment and optional
parts or attachments.
Please refer to these in accordance with the specification of the customer’s
machine.
- 4-l -
BULLDOZER’S WORK
BULLDOZER’S WORK
In addition to the cases given below, the
range of uses can be further increased by
using various attachments.
DOZING
A bulldozer digs and transports dirt in a
forward direction. Slope excavation can al-
ways be most effectively carried out by pro-
ceeding from the top downward.
LEVELING
When giving a smooth finish to a surface
that has been excavated or made from piled
soil, push a full blade of soil and drive for-
ward while operating the blade up and down
in small movements. Finally set the blade at
FLOAT, and drive at low speed in reverse,’
dragging the blade across the surface. When
doing this, to protect the blade, be careful
not to drive over stones or rocks.
CUTTING INTO HARD OR FROZEN GROUND

OR DITCHING
For digging and ditch excavation of hard or
frozen ground, tilt the blade. Even hard
ground can be dug effectively by a tilted
blade. If the ground is harder, use a ripper
attachment for better efficiency.
- 4-2 -
BULLDOZER’S WORK
FELLING AND UPROOTING
A Do not perform severe operations

uprooting by tilting the biade.
such as
A tree, 10 to 30 cm in diameter, can be felled

by giving 2 or 3 pushes with the blade held off
the ground. Next back the machine and lower
the blade to cut into the earth. Break the roots
and push them forward while digging.
Never allow the machine to butt against, or
give strong impact to a tree by operating at
high speeds.
PUSHING
Always install a pusher plate before carrying
out pushing work.
* If pusher work is carried out without using a
pusher plate, the front face of the blade or
the wear plate (for blade with wear plate)
may crack.
* Do not carry out pusher work with a U-blade.
* When welding the pusher plate, please con-
tact your Komatsu distributor.
- 4-3 -
EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER
EFFECTIVE METHOD OF OPERATION FOR DUAL

TILT .DOZER
With the dual tiltdozer, the cutting angle of
the blade can be adjusted when the pitch
button on the control lever by the operator’s
hand is pressed, so the blade angle can be
selected freely to match the working condi-
tions. When the dual tilt button is pressed, a
larger blade tilt angle can be obtained, which
gives an increased working range.
+ The semi U-dozer or the U-dozer can both
be installed on this machine.
- 4-4 -
BLADE CONDITION
Operating method Applicable operation Blade position
Single tilt l Normal operations .
Normal tilt operation
Dual titt l Dig.ging up boulders

l Side cutting operations (high
Turn the dual button places) (For semi U blade only)
ON and carry out l Horizontal dozing operations
tilt operation. from side slope (rough ground)
l Ditching operations (soft soil)
R pitch (pitch back) l Hauling

l Dozing soft soil (filling)
Turn the pitch button l Leveling operations (spreading)
ON and carry out left l Side-cutting operations (For
tilt operations semi U blade only)
S pitch (standard) O-Normal operations
F pitch (pitch dump) l Digging natural ground and

bedrock (digging hard soil)
Turn the pitch button 0 Pushing soil over cliffs
ON and carry out l Pushing-up soil
right tilt operations (Reduces spillage of soil over
the top surface of the blade,
and reduces amount of soil
carried back)
7 4-5 -
a. DOZING WORK
Dozing on level ground or downhill
l Natural ground, bedrock
A when
If you feel that
dumping
the situation is dangerous
the soil, for safety rea-
sons, use two movements to push the soil
over the edge.
1. Dig with the F pitch, and when the load

on the blade is approx. 80%, return to S
pitch and continue digging.
2. Set to R pitch which gives a larger load,
and haul the soil.
* Adjust the cutting angle to the most ef-
fective angle for rolling the soil.
3. Use F pitch to dump the soil.
F pitch S pitch
(When load on blade becomes
/ approx. 80?44
R pitch F pitch
;;
2. Hauling 3. Dumping?
.:
- 4-6 -
EFFECTIVE MEMOD OF OPERATION FOR DUAL TILT DOZER
t
0 Filling, soft soil
Carry out digging in R pitch or S pitch,
and haul in R pitch.
* if the digging is carried out in R pitch,
there is no sudden digging into the soil,
and the operation can be carried out
smoothly.
0 Hard soil (hard clay, shale, etc.)

If digging is carried out in F pitch, and
the chassis is raised and the blade is
tilted, the end bit will dig in better.
- 4-7 -
Pushing-up soil
1. Dig with S pitch.
* When digging gradually, use R pitch.
If the ground is hard, use F pitch.
2. Haul with R pitch.
* If there is any spillage of soil over the top
of the blade, change to S pitch.
3. Dump the soil with F pitch.
This dumps the soil more effectively, and
less soil is carried back after dumping.
F pitch
- 4-8 -
b. LEVELING (SPREADING) OPERATIONS

Carry out this operation with R pitch. The
end bit does not dig in, and the ground can
be leveled (or the soil can be spread)
smoothly.
* If the tilt cylinder is moved completely to
the end of its stroke, the tilt operation can-
not be carried out on one side, so move
the cylinder back slightly from the end of
its stroke to the S pitch position.
c. DITCHING OPERATIONS
If the dual tilt is used, the digging width
becomes smaller and a deeper ditch can be
dug.
If R pitch is used, the digging can be car-
ried out gradually, and this reduces the un-
evenness.
d. BOULDER RAISING OPERATIONS

Because the dual tilt greatly increases the
amount of tilt, the blade can dig in deep and
hook under the boulder. In addition, the oper-
ating stroke is large, so operations to raise
boulders can be carried out effectively.
- 4-9 -
e. SIDE-ClJl-l-ING OPERATIONS
(For semi .&blade only)
0 Carry out this operation in R pitch, and set
the end face of the end bit in contact with
the rock face to carry out cutting.
0 With the dual tilt it is possible to increase

the amount of tilt and to carry out side-
cutting operations on higher walls.
f. HORIZONTAL DOZING OPERATIONS FROM

SIDE SLOPE (rough ground)
The dual tilt can give a larger amount of
tilt, so when dozing from a side slope, this is
effective because the chassis becomes hori-
zontal after a short digging distance.
- 4-10 -
EFFECTIVE METHOD OF OPERATION FOR RIPPER

HINTS FOR EFFECTIVE RIPPING
l The most suitable digging angle for the
shank is with the shank tilted about 5” to
the ground surface (ripper point angle: 45”
to 50”).
0 When digging relatively soft rock (seismic
wave 1500 m/set or below), keeping a
shank in tilted back posture is allowed.
l When digging relatively hard rock, a shank

should not be left in tilted back posture.
Otherwise, the point tip will wear early,
causing low self-sharpening effect.
l If slippage of the tracks is found during

ripping operation, existence of a boulder or
rock is assumed. Pick up such an obstacle
by manipulating the tilt-cylinder.
When picking up a stone, advance the ma-
chine at a fixed gear speed (Fl or F2).
* When raising boulders or digging up
rockbed, do not put the transmission in
neutral. If the transmission is in neutral, the
reaction of the tilt cylinder will push the
machine back. Always operate the machine
with the transmission in FORWARD.
* Selecting a suitable ripper point to match
the rock conditions is extremely important
to ensure effective use of the ripper.
Various types of ripper are available for
each type of rock, so please refer to the
section SELECTION OF RIPPER POINT.
-4-11 -
EFFECTIVE METHOD OF OPERATION FOR RtPPER
PICKING UP STONES AND ROCKS

If the ripping operation is blocked by a
stone or rock, such an obstacle can easily be
removed by manipulating the tilt cylinder so
as to use the ripper shank as a pickax.
RIPPING AN INCLINED SURFACE

This ripper with the variable-angle shank is
more effective than the conventional rippers
on digging of inclined surfaces because of its
large reach (L).
TANDEM RIPPING
(If a giant ripper with push block is installed.)
This ripper may be used in the tandem rip-
ping method, if necessary.
- 4-12 -
METHOD OF PIN-PULLER CONTROL

(If a giant ripper is installed)
1. Stop the machine in a safe place, and
lower the shank to the ground.
2. Set the pin-puller control switch in the
PULL OUT position to remove the mount-
ing pin.
.3. Move the ripper up or down to set the

shank to the desired position.
Depth
. Max.
of holder
4. Set the pin-puller control switch in the

PUSH IN position to insert the mounting
pin. If the pin is not aligned with the hole
in the shank, put the pin-puller control
switch in the PUSH IN position and raise or
lower the ripper slowly.
* When raising the pin position and digging

deeply, use a long protector. This prevents
wear of the shank.
- 4-13 -
TIPS FOR LONGER UNDERCARRIAGE LIFE

Undercarriage life greatly varies depending
on operation method, inspection and mainten-
ance. 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.
Please consult your Komatsu distributor
when selecting track shoes.
Do not allow shoe slipping to occur during 1
operation. If shoe slipping occurs, reduce
load until slipping stops.
0 Avoid sudden starts, acceleration or stops,

unnecessarily high speeds and sharp turns.
0 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 di-
rections can be done properly. Make turns
with the largest possible radius.
l Prior to operation, clear boulders and ob-

stacles to prevent machine from riding
over them while operating.
- 4-14 -
When working on slopes, carry out oper-

ations facing up or down the slope, and
avoid operations across the slope. When
stopping the machine on slopes, also stop
the machine facing up or down the slope.
When ground inclines to left or right during
digging operation, do not continue to dig
with machine inclined. Move machine back
to level ground and start to dig again.
When idlers or sprockets are lifted due to
obstacles during dozing and ripping, do not
attempt to force the machine to perform.
Because work at this time exceeds ma-
chine working capability.
INSPECTION AND ADJUSTMENT

Properlv
. . adiust track tension. Tension
should be measured at clearance shown in
the diagram - usually 20 to 30 mm at this
point. For rocky terrain, tighten tracks
slightly. In clay or ‘sandy areas, slightly
loosen them. (For inspection and adjust-
ment procedures, refer to ‘WHEN RE-
QUIRED”.)
Check idler rollers for oil leakage as well
as for loose bolts and nuts. If any trouble
is detected, repair immediately.
- 4-15 -
INSPECTION AND REPAIR

Frequent inspection and prompt repair will
reduce repair costs. The following items for
inspection will serve as a guide to mainten-
ance service of each undercarriage part. Per-
form periodical inspection and contact your
Komatsu distributor when machine has ap-,
proached repairable limits and reversing
limits.
Measuring Height of Grouser I

After taking up. slack in track shoes,
measure height at center of shoe as shown in
the diagram.
* Standard height (H): 88 mm
* Repair limits (H): 30 mm
Measuring Outside Diameter of Track Roller

1) Measure height (size C) of link tread as
shown.
2) Stop machine at position where link
tread, whose size C has been measured
completely, contacts roller tread. Then
measure size B.
3) Calculate outside diameter of tread (size
A): A-(B--)x2
* Standard size (A): 255 mm
* Repair limits (A): 219 mm
- 4-16 -
ADJUSTMENT OF WORK EQUIPMENT

BLADE ADJUSTMENT
TILTING THE TILTDOZER

The tiltdozer can be tilted by manipulating
the blade control lever as indicated below.
Tilting adjustment to the right: 600 mm or more
Tilting adjustment to the left: 600 mm or more
When a larger tilting adjustment is re-
quired, proceed as follows:
By turning brace (1) with handle bar (2) se-
cured to the L.H. brace, the blade can be
tilted up to the max. adjustment of 1025 mm
by changing the length of the brace (Q).
* Standard distance (Q) between joints:
1460 mm
* Carry out adjustment of the length of the
brace at a range where it does not exceed
the maximum tilt. If the maximum tilt is
exceeded, there will be excessive force
brought to bear on the parts, so do not
use it in this condition.
ADJUSTING SHIM IN BLADE CYLINDER CAP

Set the standard shim adjustment in the
blade cylinder cap to 4 mm.
Remove shims to balance the wear of the
cap and the ball at the end of the piston rod.
The proper clearance to be maintained with
the shims is 0.2 to 0.5 mm.
- 4-17 -
ADJUSTING BRACE
When adjusting with two workers
Start the engine, raise the blade 300 to 400
mm off the ground, and use inching control
to tilt to the left and right. Adjustment can be
carried out easily by rotating the brace
handle while raising and lowering.
When adjusting with one woker

When extending the brace
Set the blade at FLOAT and rotate the
brace handle to adjust.
When retracting the brace

E
Set the blade on top of a block, and rotate E
the brace handle. In this way, adjustment 8
d
can be carried out easily. I I
When operated in this way, the blade is 8
m
tilted, so the handle gradually becomes t
T-
heavier. When this happens, return the -.. -
! ,I
blade from the tilt position to the horizontal lOO-10Omm ‘, 2150
- - ---.
position and turn the handle again accord-
Yll57%
ing to the procedure given above.
- 4-18 -
SHIM ADJUSTMENT
Adjust the thickness of shim so that the
ball joint play (7 points) in the axial direction
(shown by the arrow) does not exceed 1 mm.
1. Remove shim (1) and tighten bolts (2) to

eliminate the ball joint play.
2. Measure clearance (A) and remove bolts
(2).
3. Install shim (1) having its thickness of (A to
A + 1) mm in place with bolts (2).
* Confirm that ball joint can move smoothly
after tightening bolts.
- 4-19 -
ADJUSTMENT’OF WORK EQUIPMENT
RIPPER ADJUSTMENT
ADJUSTING DIGGING DEPTH
There are mounting pin holes in the shank,
and these can be changed to match the dig-
ging depth. For normal operations, use the
bottom hole; for particularly deep digging,
use the top hole.
Change the digging depth as follows.

1. Put a pointed tool in contact with pin (l),
then hit with a hammer and remove it 0
from the opposite side. 0
2. Remove pin (2), then change the position 3
of the shank hole. I
3. Push in pin (1) partially by hand, then
knock in with a hammer.
* If a giant ripper is installed, refer to %
\
0
METHOD OF PIN-PULLER CONTROL.
REPLACING POINT AND PROTECTOR

If the point and protector installed to the
tip to protect the shank are worn, replace
them.
Using a hammer and punch against the
point marked by the arrow, knock out and
remove from the opposite sidz.
* The pin is a unitized type, so insert the pin
i
P
/k
0
partially by hand, then knock it in fully with

a hammer.
- 4-20 -
PROCEDURE FOR REMOVING AND INSTALLING CAB
PROCEDURE FOR REMOVING AND INSTALLING

CAB
The person carrying out the lifting work
with a crane must possess the required quali-
fications.
A Always
strength.
use a lifting tool that has ample
REMOVING AND INSTALLING CAB

If it is necessary to remove the cab when
moving the machine between jobsites, carry
out the operation as follows.
REMOVING CAB
Removing air conditioner control cable
1. Remove clamp (1) and cable connector (2)
at the air conditioner unit end.
* The clamp and the cable connector can be
seen at the back after removing fresh air
filter (3).
2. Remove cab control panel (4) from the cab
panel, then pull out control cable (5) 20 -
40 mm.
3. Remove clamp (6) and cable connector (7)
from control panel (4).
4. Return control cable (5) (pulled out in Step 4
2) to its original position. Cable
connection
5. Install cable connector (2) and clamp (1) at Cable
the air conditioner unit end. Clam6
Install
I i
&
t
Remove
- 4-21 -
Removing panel inside cab I 1

6. Remove left and right car stereo knobs
(8) (pull out to the front), loosen the nut,
then remove holder plate (9).
7. Remove caps (10) (10 places) installed to
the top surface of the panel.
8. Remove panel mounting screws (11) and
washers (12) (18 places), then remove pa-
nels (13), (14), and (15).
Removing plates under left and right doors
9. Remove mounting screws (16) and wa-
shers (17) (left and right: 6 places), then
remove plates (18) (left and right: 2
places).
* Plate (18) is the door seal protection
plates.
Removing blind caps at cab mounting bolt
portion
10. Remove blind caps (19) (7 places) in-
stalled to the bottom front of the cab and
the bottom of the left and right doors.
* After removing the cab, install blind caps
(19) again.
Disconnecting connectors
11 Disconnect wiring harness connectors (20)
and (21) that come from the left side of
the cab.
* Hold down protrusion (P) of the connector
with your finger, then pull up and out.
* Connector (20): Air conditioner power
source, 17-pin
Connector (21): Cab, display power
source, 21 -pin
- 4-22 -
Disconnecting window washer hoses

12. Disconnect hoses (22) (4 places) coming
from the left side of the cab.
* Pull hoses (22) up and out to remove.
Removing cab
13. Remove 14 cab mounting bolts (A) - (N).
* Seal rubbers (23) (2 places) (for blocking
the clearance) are used again when in-
stalling the cab, so keep them in a safe
place.
* Weight of cab: Approx. 450 kg.
- 4-23 -
INSTALLING CAB
Install or connect all parts in the opposite
order to removal.
However, use the following procedure for the
parts given below.
l Installing cab
l Connecting control panel and control cable
Installing cab
1. Set height adjustment joint (24) installed to
the cab so that the dimension (S) in the di-
agram is less than 8 mm.
2. Lower the cab slowly from above the floor. ’
3. Align the cab with the floor frame, then in-
stall bolts and washers (A) - (N).
* Screw the bolts 3 - 4 threads; do not
screw them in fully.
4. Tighten bolts (H) - (N) fully.
* When tightening bolts (H) - (N), check that
height adjustment joint (24) installed to
bolts (A) - (G) is not in contact with the
floor frame mounting surface.
5. Screw in bolts (A) - (G) so that height ad-
justment joint (24) contacts the floor frame
mounting surface.
A Do not use a spanner to tighten the 1

Y.r i < 1 j;g
height adjustment joint after the tip

touches the floor frame surface. This will
cause deformation of the cab or floor
frame, and will generate initial stress.
- 4-24 -
6. After adjusting the joint, tighten cab

mounting bolts (A) - (G).
Connecting control panel and control cable

1. Remove clamp (1) and cable connection (2) Cab panel
\
2. Pull out control cable (5) 20 - 40 mm
from the cab. Contr
lever
3. Connect cable (7) to the control panel, then
install clamp (6). ;is
4. Push in the cable and install control panel frame)
(4) to the cab panel.
5. Install cable connection (2) and clamp (1)
* Install the cable clamp in the position
shown in the diagram on the right.
6. Operate the control lever to check the
movement of the lever.
* Lever operation: 66
Cable
connection
Cable lever
Pin
.:
Clamp
$ --Y
Remove It‘Control
cable
- 4-25 -
OPERATING THE CAR STEREO

HOW TO USE
To play a cassette tape:
1. Power source
When the power switch is turned clockwise,
power will be supplied to the car stereo.
2. Setting
When a cassette tape is inserted into the slot,
the tape is set, causing the program indicator
lamp to light.
3. Stopping
When both the FF and REW buttons are de-
pressed simultaneously, the cassette will
spring out of place and the stereo will stop.
4. Selection of program
1) Automatic selection
When one side of the tape is finished, the
tape will change direction so that there is
no interruption.
2) Manual selection
When the program selection switch is de-
pressed before one side of the tape is fin-
ished, the tape will change direction.
Radio power switch .

Volume control Program selection switch
Balance control
Tape slot FF/AEW button
Tape selection button /
\ \ /’ / Eject button
Tone quality control

~~~~~tf~mjFtiit button ~f~~~~~
button
changeover button
Program indicator lamp
- 4-26 -
5. Program indicators
The direction in which the tape is moving
during PLAY is indicated by two indi-
cators.
6. FF (fast forward), REW (rewind)
When the FF or REW button is depressed,
the button will be locked and the tape
will run in fast forward or rewind.
To release the button,
depress the button which is not de-
pressed, or
depress both the FF and REW buttons
simultaneously (At this time, the cas-
sette tape will spring out of place), or
wait until the tape finishes playing.
(After the button is automatically re-
leased, the opposite side of the tape
will start playing), or
depress the program selection button.
(After the button is released, the
other side of the tape will PLAY.)
7. Volume control
As the volume control knob is turned
clockwise, the tape plays louder.
8. Balance control
When the balance control knob is pulled
out and turned clockwise, the volume
from the R.H. speaker increases. When
turned counterclockwise, the volume from
the L.H. speaker increases.
9. Tone quality control
When the tone quality control knob is
turned clockwise, high tones will be inten-
sified. When turned counterclockwise, the
low tones will be intensified.
10. Roundness control
When the roundness control switch is de-
pressed, both the high tones and low
tones will be intensified, even if the
volume of the sound is low.
11. APC (automatic program changeover
button)
The song now playing can be played
again from the beginning or the next
song can be played again from the begin-
ning.
- 4-27 -
When listening to the radio (AM/FM):

1. AM/FM changeover
When the changeover button is kept down
(a), the radio will receive FM stations.
When the button is raised (H), the radio
will receive AM stations.
The button is changed over by simply
pressing it.
2. Station selection button
When this button is depressed, the preset
station can be heard.
3. Manual tuning
The desired station can be selected by
turning the tuning knob.
4. How to preset a station
1) Pull out the button you want to use for
the station.
2) Turn the tuning knob until it is set on
the desired station.
3) Then push the button back in.
- 4-28 -
PRECAUTIONS FOR HANDLING THE CAR

STEREO
1. When the head gets dirty, clean it with a
head cleaning tape.
2. Never touch the head with a magnet,
screwdriver, or other hard object.
3. Before using a tape, take up the looseness
by lightly turning it outward with a pencil.
4. Store tapes in a case, away from direct
sunlight and dust.
5. Do not use C-120 tapes.
6. If the stereo is not going to be used for a
long time, take the cassette out of the
stereo. Do not leave the cassette in the
stereo.
7. This stereo cassette is specified for use at
12V. Do not remove the converter.
- 4-29 -
OPERATING THE AIR CONDITIONER
OPERATING THE- AIR CONDITIONER

CONTROL PANEL
@ Inside-Outside air selector switch
Use this switch to change over the intake
vents when heating or cooling the cab.
Inside air (RECIRC q )
Air is inhaled from inside the cab.
(Generally used for cooling the inside of
the cab.)
Outside air (FRESH a )
Air is inhaled from outside the cab.
(Generally used for ventilating and heating
the inside of the cab.)
Air conditioner switch

When this switch is pressed and the blue
lamp lights up, the cooling function is
actuated.
This switch is used when cooling or dehu-
midifying.
0 Control panel
- 4-30 -
0 Blower switch
This switch is used not only to control the
flow of air in cooling and heating, but also as
the main switch.
l The air flow is controlled in three ranges,
H, M, and L.
0 When the switch is turned OFF, the power
line is disconnected and the air conditioner
stops.
@ Temperature control lever

This is used to adjust the temperature
when cooling or heating.
l If the temperature control lever is moved
down, the temperature of the air blowing
out wil be lowered.
(The water valve closes and the heating
function stops.)
l If the temperature control lever is moved
up, the temperature of the air blowing out
will be raised.
(The water valve opens and the heating
function starts.)
- 4-31 -
COOLING OPERATION
0 Control panel
Ordinary cooling
When control switches and levers are used
as shown, fresh cool air will be supplied into
the cab.
0 Push switch @.
0 Set levers 0 and @I in the positions
shown.
l Set switch 9 and lever @ in the desired
positions.
Ventilation and cooling

When the air in the cab gets dirty, move
Inside-Outside air selector lever @ to the out-
side air (FRESH) position to let outside air
into the cab. a
The other switches are used in the same
manner as in ordinary cooling.
* If ventilation cooling is used for many
hours, the cooling effect may not be suffi-
cient. When the cab has been sufficiently
ventilated, move Inside-Outside air selector
lever % back to the inside air (RECIRC)
position. Icl
0 Control panel
a
- 4-32 -
HEATING OPERATION
0 Control panel
Ordinary heating
When the control switches are used as
shown, warm air is supplied into the cab.
l Set levers @ and @I in the positions
shown.
0 Set switch @I and lever @I in the desired
positions.
Dehumidifying heating
When temperature control lever @ is
placed in the middle of “COOL” and ‘WARM”,
dehumidified air will be supplied. The other
switches are used in the same manner as in
ordinary heating.
* When dehumidifying heating is used when
the air in the cab is humid (in spring,
autumn, or rainy weather, for example), the
cab will be heated comfortably without
clouding up the windows.
Control panel
0
- 4-33 -
Precautions for using air conditioner

When co.oling, change the air occasionally.
0 When smoking and using the cooler, the
eyes may begin to hurt.
If this happens, use cooling at “OUTSIDE”
for a short time to clear out smoke in the
cab.
l When using the air conditioner for a long
period, move the knob to RECIRC. + OUT-
SIDE once every hour to change the air.
When using the cooler, make sure the hot

water circuit is completely stopped.
l If hot water is circulating in the heater, it is
like having a hot’ water bottle in the cab..
Always make sure the temperature lever is
at the COOL position.
l When not using the heater for a long
period, fully close the hot water outlet and
inlet valves at the engine water manifold
and the engine oil cooler.
Be careful not to overcool the cab.

l The cab should feel cool when entering
there from outside (5°C or 6°C lower than
the. outside temperature). It is not good for
the health to have the temperature in the
cab too low. Always. give careful consider-
ation to temperature regulation.
- 4-34 -
INSPECTION AND MAINTENANCE

Clean air filter
If the recirculation air filter or fresh air in-
take filter become clogged, the cooling or
heating capacity will drop.
Clean the air filter with compressed air
once a week.
Check tension of compressor belt Compressor pulley

If the belt is loose, it will slip and the air
conditioner will not be able to cool properly.
Periodically press the mid-point of the belt
with the finger (approx. 10 kg) and check that, 13 - 17 mm
the deflection is 13 to 17 mm.
When the belt is new, it is particularly
liable to stretch, so always adjust it after 2 to
3 days.
Drive pulley r1517d
Check volume of refrigerant (gas)
A The refrigerant used in the cooler is color-

less and odorless, and is harmless when
released ‘into the atmosphere. However if
it gets in the eyes or on the hands, it will
be cause of burn or loss of sight, so never
loosen any part of the refrigerant circuit.
If there is a lack of refrigerant, the cooling

performance will be poor. When the engine is
running at full throttle, and the cooler is run-
ning at high speed, check the condition of the
refrigerant flowing in the refrigerant circuit by
looking at the sight glass (inspection window)
on the receiver.
- 4-35 -
Condition of refrigerant I !
t’,:,:;
0’0’:.
No bubbles in flow . . . . . . . . . . . . . . . . Suitable Sight glass
Some bubbles in flow (bubbles pass con- Suitable
tinuously)
. . . . . . mm................. Lack of refrigerant 0.. Lack of
-0.’ refrigerant
0
Colorless, transparent
No refrigeranl t
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No refrigerant (colorless,
If there are any bubbles, there is a lack of eceiver transparent)
gas, so have to add refrigerant at a shop.

f151?6
If the equipment is run when there is lack
of gas, it will cause breakage of the com-
pressor.
Check during off-season

When the air conditioner is not being used,
run the compressor at low speed for a few
minutes every week to avoid loss of oil. (Run
the engine at low speed with the temperature
control lever at LOW COOL.)
* In cold weather, do not run the com-
pressor suddenly at high speed. This may
cause failure in the compressor. When the
temperature is below 2 to 6.5X, the low
pressure cut-off switch functions to stop
the compressor from running even when
the cooler switch is turned on.
- 4-36 -
Procedure for replacing receiver

Replace the receiver every two years.
After replacing the receiver, add com-
pressor oil. When adding oil, place the re-
ceiver at an angle and measure the amount
of oil remaining inside the receiver. Add the
same amount of fresh oil (Densoil 6) to the
receiver.
* The replacement interval may become
shorter according to the condition of use.
* If the receiver is used when the moisture
absorption limit of the desiccant has been
exceeded, the refrigerant circuit may
become blocked and cause the compressor
to break down.
Precautions when replacing receiver

If the blind cover of the receiver is left off
for more than 15 minutes, the moisture in
the air will be absorbed and the life of the
desiccant will be shortened. If the blind
cover is removed, connect the piping im-
mediately, then evacuate the circuit and fill
with refrigerant.
When removing the refrigerant from the re-
frigerant circuit, remove gradually from the
low pressure side to prevent the oil from
flowing out.
- 4-37 -
HANDLING OF BATTERY
HANDLING OF BATTERY
When inspecting or servicing a battery, be
sure to stop the engine and turn the starting
switch key to “OFF” position.
A cloth
Before starting the engine, use a damp
to wipe off the dust accumulated on
the top surface of the battery or on the
starting motor and the alternator.
PRECAUTIONS FOR CHARGING BATTERY
A To avoid gas explosions, do not

or sparks near the battery.
bring fire
A _lfclothes,
the electrolyte gets on your skin
immediately wash with plenty
or
of
clean water.
1. Before charging, disconnect the cable from

the negative (-) terminal of the battery.
Otherwise, an unusually high voltage will
damage the alternator.
2. While charging the battery, remove all bat-
tery plugs for satisfactory ventilation.
3. If the electrolyte temperature exceeds 45°C
stop charging for a while.
4. Turn off the charge as soon as the battery
is charged.
Overcharging the battery may cause
followings:
1) Overheating the battery
2) Decreasing the quantity of electrolyte
3) Damaging the electrode plate
- 4-38 -
HANDLING OF BATTERY
5. Do not mix up cables (positive (+) to ne- I

gative (-) or negative (-) to positive (+)),
as it will damage the alternator.
6. When performing any service to battery
besides checking the electrolyte level or
measuring the specific gravin/, disconnect
cables from the battery.
REMOVAL AND INSTALLATION OF BATTERY

l When removing battery, first disconnect
the cable from the ground (normally, from
the negative (-) terminal). If a tool touches
a cable connecting the positive terminal
and the chassis, there is danger of sparks
being emitted.
0 When installing battery, the ground cable

should be connected to the ground termi-
nal as the last step.
- 4-39 -
HANDLING OF BAITERY
STARTING ENGINE WITH A BOOSTER CABLE
A tact
When connecting
the
the cables, never con-
positive (+) and negative (-)
terminals.
A tions
Make sure that the booster cable connec-
are correct. Connect the booster
cable to the engine block as far as
possible from the battery.
When starting up the engine with a boos-

ter cable, do as follows:
1. Before connecting the booster cable
1) Size of booster cable and clip should be
suitable for the battery size.
2) Check cables and clips for breaks, cor-
roded surfaces, etc.
3) Make sure cables and clips are firmly
secured.
4) Keep the starting switch in “OFF” posi-
.
tion.
5) The battery of the running engine must
be the same capacity as that of engine
to be started.
- 4-40 -
HANDLING OF BATTERY
2. Connect the booster cables in the following

manner.
$ Connect one clip of booster ‘cable (A) to
the positive (+) terminal of the engine
to be started.
@ Connect the other clip to the positive
(+) terminal to the engine which is run-
ning.
0 Connect one clip of booster cable (B) to
the negative (-) terminal of the engine
which is running.
@ Connect the other clip to the engine
block to be started.
* Make sure the clips are firmly connected to
battery terminals. Then, start the engine.
3. Starting engine
1) Turn the starting switch to START posi-
tion and start up the engine.
2) If the engine doesn’t start at first, try
again after 2 minutes or so.
After the engine has started, the booster

cables should be disconnected. in the reverse
order in 1 hich they were connected.
1. Disconnecting the booster cables
8) Disconnect the clip of booster cable (B)
from the engine block which was
started.
3 Disconnect the other clip from the nega-
tive (-) terminal of-the running engine.
8 Disconnect the clip of booster cable (A)
from the positive (+) terminal of the
running engine.
0 Disconnect the other clip from the posi-
tive (-I-) terminal of the engine which
was started.
- 4-41 -
COLD WEATHER OPERATION

PREPARATION 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 the TABLE OF FUEL, COOLANT AND
LUBRICANTS.
COOLANT
A Antifreeze is flammable, so keep it away from any flame.
After cleaning inside of the cooling system, add antifreeze to the coolant to
prevent the coolant from freezing when the machine is not being used.
* For details of the antifreeze mixture when changing the coolant, see WHEN
REQUIRED.
Care in using Antifreeze
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor,
antifoam agent, etc.) meeting the standard requirements as shown below. With
permanent antifreeze, no change of coolant is required for a year. If it is doubt-
ful that an available antifreeze meets the standard requirements, ask the sup-
plier of that antifreeze for information.
Standard requirements for permanent antifreeze
. SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*....................... J1034
. FEDERAL STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-A-548D
* Never use methanol, ,ethanol or propanol based antifreeze.

* Where no permanent antifreeze is available, an ethylene glycol antifreeze
without corrosion inhibitor may be used only for the cold season. In this
case, clean the cooling system twice a year (in sprin.g and autumn). When
refilling the cooling system, add antifreeze in autumn, but do not add any in
spring.
* Absolutely avoid using any water leak preventing agent irrespective of
whether it is used independently or mixed with an antifreeze.
* DO not mix one antifreeze with a different brand.
- 4-42 -
BATTERY
A plenty
If the electrolyte gets
of clean water.
on your skin or clothes, immediately wash with
A To avoid gas explosions, do not bring fire or sparks near the battery.
As ambient temperature drops, battery capacity will drop, and electrolyte

may sometimes freeze if battery charge is low. Maintain battery at a charge
level of approx. 100% and insulate it against cold temperature so that
machine can be readily started the next morning.
* Measure specific gravity of fluid and obtain rate of charge from the following
conversion table:
Temp.
of fluid
2o’c O’C -1o’c -20x
Rate of
charge
100% 1.28 1.29 1.30 1.31

90% 1.26 1.27 1.28 1.29
80% 1.24 ‘1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
* When electrolyte level is low, add distilled water in the morning before work .
instead of after the day’s work. This is to prevent fluid from freezing at
night.
- 4-43 -
CAUTIONS AFTER COMPLETION OF WORK

To prevent mud, water, or the undercarriage from freezing and making it im-
possible for the machine to move on the following morning, always observe
the following precautions.
Mud and water on the machine body should be completely removed.
This is to prevent damage to the seal caused by mud or dirt getting inside
the seal with frozen drops of water.
Park the machine on concrete or hard ground. If this is impossible, park the
machine on wooden boards.
Drain water collected in fuel system so that such water may be frozen at
night.
As battery capacity drops at low ambient temperature, cover the battery or
remove it from the machine to be kept warm at night.
AFTER COLD WEATHER

When weather becomes warm, perform the fol!owing without fail:
Replace lubricating oils for various units with the ones specified for warm-
weather use.
If for any reason permanent antifreeze cannot be used, and an ethyl glycol
base antifreeze (winter, one season type) is used instead, or if no
antifreeze is used, drain the cooling system completely, then clean out the
inside of the cooling system thoroughly, and fill with fresh water.
As the APS (Automatic Priming System) becomes useless (at 15°C or above),
be sure to close the fuel valve for the APS.
-4&I-
STORAGE
STORAGE
BEFORE STORAGE
To place the machine in storage for an extended period of time, the follow-
ing measures must be taken to insure that it can be returned to operation with
minimum of service.
After every part is washed and dried, the machine shall be housed in a dry
building. Never leave it outdoors.
In case it is indispensable to leave it outdoors, lay wood plates on the
ground, and park the machine on the wood plates and cover it with
canvas etc.
Completely fill fuel tank, lubricate and change oil before storage.
Apply a thin coat of grease to metal surface (hydraulic piston rods).
As to batteries, remove the terminals and cover them, or remove them from
the machine and store separately.
When the ambient temperature is anticipated to drop below O”C, always add
antifreeze in the cooling water.
Lock each work equipment control lever with the safety lock and place the
fuel control lever in the ENGINE STOP position. Do not lock the brake pedal;
use blocks to stop the machine from moving.
Put each switch in OFF position.
Prevent any water from getting into the exhaust pipe and other parts.
- 4-45 -
STORAGE
DURING STORAGE
A the
If it is unavoidably necessary to carry out rust-preventive operation while
machine is indoors, open up doors and windows to improve ventilation
and prevent the gas poisoning.
Operate the engine and move the machine for a short distance once a
month so that new oil film will be coated over movable parts and component
surfaces.
* Before operating the work equipment, wipe off the grease on the hydraulic
piston rod.
AFTER STORAGE
Carry out the following procedure when taking the machine out of long-term
storage.
l Wipe off the grease on the hydraulic piston rod.
l Completely fill fuel tank, lubricate and add oil.
* If the machine is stored without carrying out the monthly rust prevention
operation, request your Komatsu distributor for service.
- 4-46 -
OPTIONAL PARTS, AlTACHMENT
OPTIONAL PARTS, ATTACHMENT

SELECTION OF TRACK SHOES ............................................... 5-2
SELECTION OF RIPPER POINT ................................................ 5-3
- 5-l -
SELECTION OF TRACK SHOE
SELECTION OF TRACK SHOE

Please select suitable track shoes to match the operating conditions.
Track shoe
Category Use Jobsite
width
This shoe can be used for a wide range of work

Bedrock, normal from crushed rock to general civil engineering work
A 610 mm
soil such as reclamation of residential land. There is no
particular limit to its use.
Use this shoe for general soil, such as where the

main work is scraperwork and pusher work, re-
claiming land for golf courses, or stripping the
B Normal soil overburden for coal mines. This shoe cannot be 610 mm
used on bedrock. On jobsites where there are rocks
in the soil, be careful to avoid letting the machine
mount the rocks.
Use this shoe on soft ground where the shoe in

category B sinks into the ground. Do not use this 710 mm
C Soft soil shoe on jobsites where there are rocks in the soil.
Use this shoe for even softer ground. 760 mm
If a track shoe which is wider than necessary is used, the load on the track
will be increased, and this will lead to problems such as curvature of the
shoes, cracking of the links, breakage or falling out of the pins, and loosening
of the bolts.
- 5-2 -
SELECTION OF RIPPER POINT

Procedure for selecting ripper point
No
Is wear fast? -
G?
t
Yes
Yes
NO
Excessive generation
of heat at point (Less than 70%)
[Only tip of point
Install No
I3
‘_
- 5-3 -
Typical type of rock Suitable point

Selection Type of
Hardness Features Features/(Part No.) Shape
rock
@I - soft - Little quartz, Point for lime stone
little wear - Symmetric shape
Shale,
- Deposited in layers, - Yellow
lime stone
t so ripping is easy - Short
Hard (17M-78-21350)
soft Standard point
- Symmetric shape
All type of
:@- - - Yellow
general
- Short
rock
I - Turn and use again
Hard (195-78-21331)
soft - Proportion of quartz - Non-symmetric shape
is extremely high - Yellow
O- Sandstone
I (70% - 95%), point - Long
Medium wears rapidly (195-78-29130)
@J- so* . Proportion of quartz * Non-symmetric shape

is not so high - Red
I
Basalt (40 - 70%) - Long
andesite, Rock is not in layers (195-78-29140)
granite, or seams, so heat is - Symmetric shape
chert generated at point, - Red
point wear rapidly, - Short
ripping is difficult (195-78-21333)
@’ - Hard
- 5-4 -
TROUBLE SHOOTING GUIDE
- 6-l -

This guide is not intended to cover every conditions, however many of the
more common possibilities are listed.
ELECTRICAL SYSTEM
Lamp does not glow brightly even when engine runs at high speed.
Lamp flickers while engine runs.
l inspect and repair the wiring.
0 Adjust belt tension.
Charge monitor does not go out even when engine runs at high speed.
l Replace the alternator.
0 inspect and repair the wiring.
Unusual noise is emitted from the alternator.

l Replace the alternator.
Starting motor does not turn when starting switch is turned on.
. 0 Inspect and repair the wiring.
0 Charge the battery.
The pinion of the starting motor keeps going in and out.

l Charge the battery.
Starting motor turns the engine sluggishly.

l Replace the starting motor.
Starting motor disengages before the engine starts up. ’

l Inspect and repair the wiring.
Engine perheating monitor does not light.

(When the temperature of the engine cooling water exceeds 2O”C, this condi-
tion is normal.)
l Check and repair wiring.
0 Replace the timer.
0 Replace the monitor.
l Replace the glow plug.
- 6-2 -
Engine oil pressure monitor does not light up when engine is stationary
(when the starting switch is in ON position.)
0 Replace the monitor.
l Replace the caution lamp switch.
Charge monitor does not light up when the engine is stationary. (When the
starting switch is in ON position.)
l Replace the monitor.
l Inspect and repair the wiring.
- 6-3 -
ENGINE
Engine oil pressure monitor flashes when engine speed is raised after com-
pletion of warm-up.
l Add the oil to the specified level.
l Replace the oil filter cartridge.
l Check oil leakage from the pipe or the joint.
l Replace the monitor.
Steam is emitted from the top part of the radiator (the pressure valve).
Radiator cooiing water level monitor flashes.
Supply the coolig water and check leakage.
Adjust fan belt.
Wash out inside of cooling system.
Clean or repair the radiator fin.
Replace the thermostat.
Tighten the radiator cap firmly or replace the gasket of it.
Replace the monitor.
Engine does not start when the starting motor is turned over.
Add fuel.
Repair where air is leaking into fuel system.
Replace the injection pump or the nozzle.
Check the valve clearance.
Check engine compression pressure.
Refer to the section of electrical system.
Exhaust gas is white or blue.

l Adjust to specified oil quantity.
l Replace with specified fuel.
Exhaust gas occasionaly turns black.

l Clean or replace the air cleaner element.
l Replace the nozzle.
l Check engine compression pressure.
l Clean or replace the turbocharger.
- 6-4 -
Combustion noise occasionally changes to breathing sound.

8 Replace the nozzle.
Unusual combustion noise or mechanical noise.

l Replace with specified fuel.
l Check over-heating.
8 Replace the muffler.
0 Adjust valve clearance.
- 6-5 -
CHASSIS
Oil pressure in torque converter fails to rise.

0 Check and repair where air is leaking into oil pipe and pipe joint.
l Check and replace gear pump.
l Add oil to transmission case.
0 Check and replace transmission filter.
Torque converter is overheats.

0 Replace fan belt.
l Refer to the section ENGINE.
0 Clean or replace oil cooler.
0 Refer to the item “oil pressure in torque converter fails to rise”.
0 Check and replace gear pump.
Torque converter oil temperature gauge does not work

l Replace oil gauge
0 Check and repair connection.
Insufficient tractive force.

0 Refer to the section ENGINE.
l Refer to the item “oil pressure in torque converter fails to rise”.
l Check and replace steering clutch disc.
Machine doesn’t start by engaging the gear shift lever.

0 Add oil to steering clutch case.
0 Refer to the item “oil pressure in torque converter fails to rise”.
0 Check and replace gear pump.
0 Clean oil strainer.
- 6-6 -
When steering lever on one side is pulled, machine continues to travel

straight forward instead of turning.
0 Adjust brake.
Machine doesn’t stop when brake pedal are deressed.

l Adjust brake.
Track comes off.

Sprocket develops abnormal wear.
l Adjust track tension.
Blade rises too slowly or does not rise at all (or blade tilts too slowly)
0 Add the oil to the specified level.
Ripper moves too slowly.

l Add the oil to the specified level.
Insufficient force of ripper

l Retighten and repair hydraulic oil piping.
- 6-7 -
APS (Automatic Priming System)
Engine does not start at all.

8 Clean and replace nozzle.
l Replace glow plug.
l Check and repair fuel piping.
l Replace fuse.
l Replace APS controller.
Engine does start smoothly but much white smoke emits or the engine stops.
Clean and replace nozzle.
Replace glow plug.
Replace fuse,
Check and replace alternator.
Replace APS watertemperature sensor.
Replace APS controller.
When loaded, the engine will emit black smoke and stop.
Burner is ignited and preheat monitor lamp remaining lighted.
l Replace APS water temperature sensor.
l Replace heater relay.
Preheat monitor lamp does not become bright.

(When the temperature of the engine cooling water exceeds ZOT, the
engine preheating system is in normal condition.)
l Replace preheat monitor lamp or glow plug.
l Repface timer.
Burner is not ignited.

l Refer to the above item.
l Clean and replace nozzle.
l Replace APS controller.
SERVICE METER, SERIAL NUMBERS, LUBRICANTS
SERVICE METER, SERIAL NUMBERS,

LUBRICANTS
SERVICE METER ............................................................. 7-2

MACHINE AND ENGINE SERIAL NUMBERS ................................... 7-3
FUEL, COOLANT AND LUBRICANTS .......................................... 7-4
- 7-l -
SERVICE METER
SERVICE METER
This meter indicates the integrated work
hours. So, use it according to the following
instructions.
0 Record the readings at the start and the

end of work, this is the work record of the
machine.
0 This record will indicate, when periodical
maintenance is due.
0 It also indicates the integrated working
hours when machine problems are en-
countered.
* How the meter progresses
The service meter progresses by 1 when
the engine is operated for one hour, re-
gardless of the engine speed.
Consequently, if the engine is running, the
service meter will advance even if the ma-
chine does not move.
0 While engine is running, green pilot lamp
on the service meter flashes to show the
service meter advances.
- 7-2 -
MACHINE AND ENGINE SERIAL NUMBERS
MACHINE AND ENGINE SERIAL NUMBERS .
When calling for service of mechanic or

when making replacement parts order, be
sure to give your Komatsu distributor the ma-
chine and engine serial numbers as well as
the service meter reading beforementioned.
These numbers are found on the plates
shown in the figures.
Location of the machine serial number plate

...on the lower part of right side console
box
Location of the engine serial number plate

. ..on the upper left side of the engine cylinder
block, when seen from the fan side.
- 7-3 -
FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY (P)

CIND OF
RESERVOIR
FLUID
-22 -4 14 32 50 69 96 104 1221 Specified Refill
-30 -20 -10 0 10 20 30 40 5OY I
Engine oil pan 63 51
Power train oil pan

(incl. transmission,
170 120
torque converter and
bevel gear cases)
Engine oil
Final drive case 43 (each) 43 (each)
Damper case 2.1 2.1
Hydraulic system
Fuel tank Iiesel fuel
Cooling system Water
% ASTM 0975 No. 1
- 7-4 -
NOTE:
(l)When fuel sulphur content is less than 0.5%, change oil in the oil pan
every periodic maintenance hours described in this manual.
Change oil according to the following table if fuel sulphur content is above
0.5%.
Change interval of oil in

Fuel sulphur content
engine oil pan
I
0.5 to 1.0% l/2 of regular interval

~~ I ~~~
Above 1 .O% l/4 of regular interval

I
(2)When starting the engine in an atmospheric temperature of lower than

O”C, be sure to use engine oil of SAElOW, SAElOW-30 and SAE15W-40,
even though an atmospheric temperature goes up to 10°C more or less in
the day time.
(3)Use API classification CD as engine oil and if API classification CC, reduce
the engine oil change interval to half.
(4)There is no problem if single grade oil is mixed with multigrade oil
(SAElOW-30, 15W-40), but be sure to add single grade oil that matches
the temperature in the table on the left.
(5)We recommend Komatsu genuine oil which has been specifically formu-
lated and approved for use in engine and hydraulic work equipment
applications.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil 1
in piping.
Refill capacity: Amount of oil needed to refill system during normal inspec-
tion and maintenance.
- 7-5 -
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAEl OW, 30.40
JO. Supplier [GL-O or GL-51 [Lithium-Base] [Ethylene Glycol
1 0w30.15w40
SAEBO, 90,140 NLGI No. 2 Base]
(The 15W40 oil
Permanent Type
marked l is CE.)
EOl O-CD
AF-ACL
EOBO-CD GO90 G2-Ll
AF-PTL
T KoMATSU EOlO-30CD GO140 GZ-LI-S
AF-PT (Winter, one
EOl5-40CD
season type)
Diesel sigma S
Super dieselmulti-
2 AGIP Rotra MP GR MU/EP
grade
*Sigma turbo
RYKON prenium
3 AMOCO *Amoco 300 Multi-purpose gear oil
grease
Litholine HEP 2
4 ARC0 lArcofleet S3 plus 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
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
‘Turbomax EPX
MS3
7 CASTROL *RX super HYP~V Anti-freeze
Spheerol EPL2
CRD HYPOY B
HYP~Y C
8 CHEVRON lDelo 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
lEssolube XD-3
11 EXXON Gear oil GP
lEssolube XD-3 Extra Gear oil GX Beacon EP2 All season coolant
(ESSO)
lEsso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifreeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolanl
Delvac 1300 Mobilux EP2

Mobilube GX
13 MOBIL ‘Delvac super Mobilgrease 77
Mobilube HD
1 ow-30. 15w-40 Mobilgrease special
- 7-6 -
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAEl OW. 30.40
io. Supplier [GL-4 or GL-51 [Lithium-Base] [Ethylene Glycol
1 0w30.15w40
SAE80,90,140 NLGI No. 2 Base]
(The 15W40 oil
Permanent Type
marked l is CE.)
Multi-purpose white
*Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL summer coolant
fleet motor oil Multi-purpose 4140 707L White - bearing
grease
FINA potonic N
15 PETROFINA FINA kappa TO FINA marson EPL2 FINA tamidor
FINA potonic NE
Spirax EP -
I6 SHELL Rimula X Alvania EP grease
Spirax heavy duty
Sunoco ultra prestige

2EP Sunoco antifreeze
17 SUN Sunoco GL5 gear oil
and summer coolant
Sun prestige 742
*Ursa super plus Multifak EP2 Code 2055 startex

I8 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolanl t
Rubia S Total EP
19 TOTAL Multis EP2 Antigeliantifreeze
lRubia X Total transmission TM
20 UNION *Guard01 MP gear lube LS Unoba EP
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear 8 Antifreeze
MDC Multigear C
- 7-7 -
KOMATSU DRESSER COMPANY
Fax No. (708) 367-2987
801 East Sunnyside Avenue
PROPOSAL FOR MANUAL REVISION
Libertyviile, IL 60048 U.S.A.
Altn: Technical Publications
FOR INTERNAL USE ONLY - No. PMR
’ NAME OF COMPANY: LOCATION:
: PHONE NO:
>
i 1 DEPARTMENT: DATE:
I
I~
; NAME:
I
4ANUAL NAME:
JlANUAL NO:
JlACHlNE MODEL:
j/N IF APPLICABLE:
‘AGE NO:
‘ROBLEM:
Attach photo or sketch.

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

:ORRECTIVE ACTION:
PMRll93

Operation & Maintenance Manual: Bulldozer

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SEAM000301

BREAKING IN YOUR NEW MACHINE

/EXPLANATION OF SYMBOLS o-2

I BREAKING IN YOUR NEW MACHINE o-2

/ SAFETY HINTS. . . A l-l

I OPERATING INSTRUMENTS 4-l

TROUBLE SHOOTING GUIDE 6-l

/ SERVICE METER, SERIAL NUMBERS, LUBRICANTS 7-l

Read the Operation and Maintenance Ma-

Exhaust gas is dangerous. When running

When operating inside a building always be

trances, aisles, etc. and the load limit of

Do not allow an open flame to come near

BEFORE STARTING OPERATION

l When getting on or off the machine, use

Do not leave parts or tools lying around in

Check the level of the fuel, lubricants and

l To ensure the safety of workers near the

AFTER STARTING THE ENGINE t ‘-.

Operate the blade and ripper to confirm

0 Move the machine slowly and listen care-

l Choosing a safe place, turn the machine to

whether it is safe before continuing work.

l The work area should be made as flat as

The machine should always be operated at

Be careful of those around you, and al-

When traveling the machine, keep the

Do not allow unauthorized persons into the

Always be aware of the operating capacity

0 The machine condition can be judged from

If the machine breaks down and needs to

Check the load limits of bridges before

0 Wherever possible, avoid traveling over

0 Never mount over an obstacle at an

0 When operating at the edge of a cliff or on

0 At the instant when the soil is dumped

0 When dumping soil over a cliff, dump

0 When working on river embankments or

When operating on slopes, remember the

0 When going down a slope, use the en-

0 As far as possible, avoid turning the ma-

In forest areas, do not mount fallen

l When operating in water or in muddy

0 If the machine gets stuck in mud, it is

l Be careful of buried objects (water pipes, gas

l When operating at night, remember the fol-

o At night it is very easy to make mis-

l When operating in fog, mist or smoke,

l When operating in snow, or cleaning snow,

Fuel or oil are dangerous substances.

When working with others, choose a group

l *Do not handle electrical equipment while

Exhaust gas is dangerous. When working

Unless you have special instructions to the

Always remember that the hydraulic oil cir-

lever to “NEUTRAL”, apply the brake lock

0 Hang a caution sign in the operator’s com-

Flames should never be used instead of

Be particularly careful when removing the

l When adding oil or fuel, do not let the oil

l When handling the cutting edges, always III

ment, place the attachment in a stable con-

METHOD FOR GETTING ON 06 OFF THE