D75 Op e Man

EMISSION CONTROL WARRANTY
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)
1. Products Warranted
Komatsu America International Company. Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collecttvely “Komatsu”) produce and/or
market products under brand names of Komatsu. Dresser. Dressta. Haulpak and Galion. This emissions warranty applies to new engines bearing the
Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to
these engines produced on or after January I. 2000. This warranty will be administered by Komatsu distribution in Canada.
2. Coverage
Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform. at the
time of sale by Komatsu. with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in
workmanship or material which would cause it not to meet these regulations within five years or 3.000 hours of operation, whichever occurs tirst. as
measured from the date ofdelIvery of the engine to the ultimate purchaser.
3. Limitations
Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for
failures or damage resulting from what Komatsu determines to be abuse or neglect, includin,,(7 but not limited to: operation without adequate coolant
or lubricants; over fueling; over speed& lack of maintenance of lubricating, cooling or intake systems; improper storage, starting. warn-up. run-in
or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water,
dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs. “downtnne” expense. related damage, tines. all business
costs or other losses resulting from a warrantable failure.
KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICUALR PURPOSE.
GARANTIE SUR LE CONTR~LE DES EMISSIONS
~NONCG DE GARANTIE SUR LE CONTR~LE DES OMISSIONS (APPLICABLE AU CANADA SEULEMENT):
Produits garantis:
Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/au font la
mise en marche de prod&s portant les noms de marque Komatsu, Dresser. Dressta. Haulpak et Galion. Cette garantie sur les emissions s’applique a tous les
nouveaux moteurs pottant le nom Komatsu, install& dans ces prodmts et utilises au Canada dans des machines concues pour utihsation industrielle non-
rout&e. Cette garantie s’applique seulement sur les moteurs produits a partir du ler Janvier 2000. Cette garantie sera administree par la distribution de
Komatsu au Canada.
Couverture:
Komatsu garantit a I’acheteur ultime et chaque acheteur subsequent que le moteur est concu, construit et Cquipt en toute confonnite. au moment de la vente
par Komatsu. avec tomes les Reglementations fed&ales americaines sur les emissions applicables au moment de la fabrication et qu’il est exempt de defauts
de construction ou de materiaux qui auraient pour effet de contrevenir a ces reglementations en dedans de 5 ans ou 3000 heures d’operation, mesure a partir
de la date de livraison du moteur au client ultime.
Limitations:
Les bris, autres que ceux resultant de defauts de materiaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour
bris ou dommages resultant de ce que Komatsu determine comme etant de I’abus ou negligence, incluant mais ne se limitant pas a: I’operation sans
lubrifiants ou agent refroidissants adequats; la suralimentation d’essence; la survitesse; le manque d’entretien des systemes de lubritication, de
refroidissement ou d’entree; de pratiques non-propices d’entreposage, demise en marche, de rtchauffement. de conditionnement ou d’arret: les
modifications non-autorisees du moteur. De plus, Komatsu n’est pas responsable de bris causes par de I’essence inadequate ou de I’eau, des saletes ou autres
contaminants dans I’essence. Komatsu n’est pas responsable des reparations non-reliees au moteur, des dtpenses encoumes suite aux temps d’arrets, des
dommages relatifs, amendes. et de tout autre codt d’affaires ou autres pertes resultant d’un bris couvert par la garantie.
KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSkQUENTS.
Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE
GARANTIE, EXPRESSE OU SOUS-ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIkRE.
CEHQ000700 - Komatsu America International Company 12199

INFORMATION IMPORTANTE SUR LE MOTEUR
CE MOTEUR EST CONFORME AUX NORMES AMERICAINES DB’EPA (ANNCE DU DES BLESSURES PEUVENT RisULTER ET LA GARANTIE
MODCLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI- S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU CALTITUDE
TION PAR COMPRESSION. CE MOTEUR EST CERTIFIt POUR OPERATION A ESSENCE EXCkDENT LES VALEURS MAXIMALES PUBLIEES POUR CE
DIhEL. (_ MODE.,&,:,TlON: ;
\
\
IMPORTANT ENGINE INFORMATION
THIS ENGINE CONFORMSTO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA
REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI-
FIED TO OPERATE ON DIESEL FUEL.
WARNING
INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL R4TE RPM OR ALTITUDES EXCEED ’
PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.
. ENGINE MODEL SERIAL NO. - DBPLACEMENT
. ENGINE FAMILY DISPLACEMENT LITERS -

EXHAUST EMISSION
FIRING ORDER l-5-3-6-2-4
CONTROL SYSTEM .
ADV. LOAD OUTPUT Kw ( HP) RPM
(CHARGE DE SORTIE ADV. +
VALVE LASH IN. EX. FUEL RATE mm3/STROKE-

COLD (mm) AT ADV.
\bTAUX D’ESSENCE AADV. )
IDLE SPEED RPM FAMILY EMISSION LIMIT

INITIAL INJECTION DEG. BTDC DATE OF MANUFACTURE -
TIMING LA FAMILLE
RkGLAGE DE UALLUMAGE - KOMATSU LTD.

INJECTION INITIALE MADE IN JAPAN
ENGINE DATAPLATE - ENGLISH / FRENCH

1. FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and
effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been
lost or has become dirty and can not be read, request a replacement manual from Komatsu or your
Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available
information of your machine or for questions regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area.
Consult Komatsu or your Komatsu distributor for those items you may require.
A WARNING
Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in a readily available place near the machine (on machines with cab, there is
a door pocket to hold the manual), and have all personnel involved in working on the machine
read the manual periodically.
Where to keep this manual. -I See “11.8 MANUAL POCKET”.
Some actions involved in operation and maintenance of the machine can cause a serious accident,
if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for you and others. In no event should you or others engage in prohibited
uses or actions as described in this manual.
Komatsu delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and specifications
that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor before operating the machine.
The description of safety is given in SAFETY INFORMATION on page O-2 and in SAFETY from page
l-l.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive
harm.
O-l
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and
maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings
in this manual and on the machine before performing operation and maintenance.
To identify safety messages in this manual and on machine labels, the following signal words are
used.
A DANGER - This word is used on safety messages and safety labels where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages or labels usually describe precautions that must be taken to avoid the
hazard. Failure to avoid this hazard may also result in serious damage to the
machine.
A WARNING - This word is used on safety messages

potentially
and safety labels where there is a
dangerous situation which could result in serious injury or death if
the hazard is not avoided. These safety messages or labels usually describe
precautions that must be taken to avoid the hazard. Failure to avoid this hazard
may also result in serious damage to the machine.
A CAUTION - This word is used on safety messages and safety labels for hazards which could
result in minor or moderate injury if the hazard is not avoided. This word might
also be word for hazards where the only result could be damage to the machine.
NOTICE - This word is used for precautions that must be taken to avoid actions which
could shorten the life of the machine.
Safety precautions are described in SAFETY from page l-l.

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact your
Komatsu distributor.
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3. INTRODUCTION
3.1 INTENDED USE

This Komatsu DOZER SHOVEL is designed to be used mainly for the following work:
l Excavation
0 Leveling
l Back filling
l Loading
See the section “12.10 WORK POSSIBLE USING DOZER SHOVEL” for further details.
3.2 FEATURES
l Since the Komatsu S6D125E-2 low fuel-consumption-type engine is mounted, and high production
for fuel (m3/e)results, use of this machine is economical.
l Since the dumping clearance is large, this machine can load 20-ton dumptrucks easily.
l Large production is secured by the bucket whose capacity is equal to 2.2m3, powerful engine and
large digging force.
l The rigid and large undercarriage produces high power.
l With the inching pedal, this machine can scoop the ground as easily as a direct drive machine.
l The decelerator pedal is installed as standard.
3.3 BREAKING IN THE MACHINE
Your Komatsu machine has been thoroughly adjusted and tested before shipment.
However, operating the machine under severe conditions at the beginning can adversely affect the
performance and shorten the machine life. Be sure to break in the machine for the initial 100 hours (as
indicated by the service meter.)
During breaking in:
l Idle the engine for 5 minutes after starting it up.
l Avoid operation with heavy loads or at high speeds.
l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of
emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only
those that apply when this product is used for the specified purpose. If the machine is used for a purpose
that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
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4. LOCATION OF PLATES, TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION

The machine serial No. plate is attached to the left side of the
operator’s seat.
4.2 ENGINE SERIAL NO. PLATE POSITION

The engine serial Nd. plate is attached to the left side of the
cylinder block of the engine.
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:
Distributor name:
Address: Phone:
Service personnel for your machine:
REMARKS
o-4
5. CONTENTS
1. Foreword ............................................................................................................................................ 0- 1
2. Safety information ............................................................................................................................ o- 2
3. Introduction ........................................................................................................................................ 0- 3
4. Location of plates, table to enter serial No. and distributor ...................................................... 0- 4
SAFETY
6. General precautions .......... ....... .. ... ........ ... ....... ..... ..... .. ...... ..... ............. ...... ... ... ............. .......... ......... .. I- 2
7. Precautions during operation .......................................................................................................... I- 7

7.1 Before starting engine ............................................................................................................. I- 7
7.2 After starting engine ................................................................................................................ I-IO
7.3 Transportation .......................................................................................................................... 1-15
7.4 Battery ....................................................................................................................................... 1-16
7.5 Towing ...................................................................................................................................... 1-18
6. Precautions for maintenance ........................................................................................................... 1-19

8.1 Before carrying out maintenance .......................................................................................... I-19
8.2 During maintenance ................................................................................................................ l-23
9. Position for attaching safety labels ................................................................................................ l-28

9.1 Position for attaching safety labels ....................................................................................... l-28
OPERATION
10. General view ...................................................................................................................................... 2- 2

10.1 General view of machine ........................................................................................................ 2- 2
10.2 General view of controls and gauges ................................................................................... 2- 3
11. Explanation of components ............................................................................................................. 2- 4

11.1 Meters and lamps .................................................................................................................... 2- 4
11.2 Switches .................................................................................................................................... 2- 6
11.3 Control levers, pedals.. ............................................................................................................ 2- 8
11.4 Fuse box ................................................................................................................................... 2-12
11.5 Dust indicator ........................................................................................................................... 2-13
11.6 Power pickup connectors ........................................................................................................ 2-13
11.7 Lift arm stay ............................................................................................................................. 2-14
11.8 Manual pocket .......................................................................................................................... 2-14
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12. Operation . ... ...... ... ... ...... .... .. ........... ............. ...... ...... ...... ...... ...... .......... ......... ... ..... ... ........ .................... 2-l 5
12.1 Check before starting engine ................................................................................................. 2-15
12.2 Starting engine.. ....................................................................................................................... 2-28
12.3 Operations and checks after starting engine.. ...................................................................... 2-31
12.4 Moving machine ...................................................................................................................... 2-33
12.5 Shifting gear ............................................................................................................................. 2-34
12.6 Shifting between forward and reverse.. ................................................................................ 2-35
12.7 Steering machine ..................................................................................................................... 2-36
12.8 Stopping machine.. .................................................................................................................. 2-38
12.9 Precautions for operation ....................................................................................................... 2-40
12.10 Work possible using dozer shovel ......................................................................................... 2-41
12.11 How to use inching pedal.. ..................................................................................................... 2-43
12.12 Parking machine ...................................................................................................................... 2-47
12.13 Check after finishing work ...................................................................................................... 2-48
12.14 Stopping engine.. ..................................................................................................................... 2-49
12.15 Check after stopping engine.. .................................................................................................. 2-50
12.16 Tips for longer undercarriage life .......................................................................................... 2-51
13. TransDortation .. .. ...... ...... ...... ..... ....... .... .. ...... ... ... ...... ............ ............. ......... .. ...... ............ ................... 2-54
13.1 Loading, unloading work ........................................................................................................ 2-54
13.2 Precautions for loading, and securing the machine.. .......................................................... 2-55
13.3 Lifting the machine .................................................................................................................. 2-56
13.4 Precautions for transportation ................................................................................................ 2-59
14. weather operation .................................................................................................................... 2-60

14.1 Precautions for low temperature ........................................................................................... 2-60
14.2 After completion of work.. ...................................................................................................... 2-61
14.3 After cold weather ................................................................................................................... 2-62
15. Long-term storage ............................................................................................................................. 2-63

15.1 Before storage .......................................................................................................................... 2-63
15.2 During storage ......................................................................................................................... 2-63
15.3 After storage.. ........................................................................................................................... 2-63
16. Troubleshooting ................................................................................................................................. 2-64

16.1 After running out of fuel.. ....................................................................................................... 2-64
16.2 If battery is discharged ........................................................................................................... 2-64
16.3 Other trouble ............................................................................................................................ 2-67
O-6
5. CONTENTS
MAINTENANCE
17. Guides to maintenance ..................................................................................................................... 3- 2
18. Outlines of service ............................................................................................................................ 3- 4

18.1 Outline of oil, fuel, coolant ..................................................................................................... 3- 4
18.2 Relating to electric system ..................................................................................................... 3- 6
19. Wear parts list ................................................................................................................................... 3- 7
20. Use of fuel, coolant and lubricants according to ambient temperature ................................... 3- 8
21. Standard tightening torques for bolts and nuts ........................................................................... 3-12
21 .I Introduction of necessary tools.. ............................................................................................ 3-12
21.2 Torque list.. ............................................................................................................................... 3-13
22. Periodic replacement of safety critical parts ..... ........... ...... ...... ...... ... .. ....... ............ ............. .......... 3-14
23. Maintenance schedule chart ... ............. ....... .. ... ... ... ......... ... ...... .. .. ........ ..... .. ... .. ....... .... ......... .. .......... 3-15
24. Service Procedure .............................................................................................................................. 3-18

24.1 Initial 250 hours service .......................................................................................................... 3-18
24.2 When required ......................................................................................................................... 3-19
24.3 Check before starting .............................................................................................................. 3-29
24.4 Every 50 hours service.. .......................................................................................................... 3-36
24.5 Every 250 hours service .......................................................................................................... 3-38
24.6 Every 500 hours service.. ........................................................................................................ 3-45
24.7 Every 1000 hours service ........................................................................................................ 3-48
SPECIFICATIONS
25. Specifications .... ..... ........ ..... ........ .......... .. .... .. .... .... .... .... ...... ...... ....... ............. ............. ... ....... .............. 4- 2
OPTIONS, ATTACHMENTS
26. Installation of fire extinguisher .... ............ ...... ...... ...... ..... ...... ............. ............. ............. ............. ....... 5- 2
27. Handling with cabin installed ........................................................................................................... 5- 3

27.1 How to read lamps and use switches.. ................................................................................. 5- 3
27.2 Fuse box ................................................................................................................................... 5- 5
27.3 Door lock.. ................................................................................................................................. 5- 6
27.4 When required ......................................................................................................................... 5- 6
27.5 Precautions for work ............................................................................................................... 5- 7
28. Operation of airconditioner.. ............................................................................................................. 5- 8

28.1 Name of each part of control panel ...................................................................................... 5- 8
28.2 Operation method .................................................................................................................... 5- 9
28.3 Precautions for use of airconditioner .................................................................................... 5-12
28.4 Inspection and maintenance ................................................................................................... 5-13
29. General precautions ........................................................................................................................... 5-15

29.1 Safety precautions ................................................................................................................... 5-15
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O-8
SAFETY
result in serious injury or death.
This safety section also contains precautions for optional equip-

ment and attachments.
l-l
a WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.
SAFETY RULES
l Only trained and authorized personnel can operate and maintain the machine.
l Follow all safety rules, precautions and instructions when operating or performing maintenance
on the machine.
l Do not operate the machine if you are not feeling well, or if you are taking medicine which will
make you sleepy, or if you have been drinking. Operating in such a condition will adversely affect
your judgement and may lead to an accident.
l When working with another operator or with a person on worksite traffic duty, be sure that all
personnel understand all hand signals that are to be used.
l Always follow all rules related to safety.
4 SAFETY FEATURES 1
l Be sure that all guards and covers are in their proper position. Have guards and covers repaired
if damaged.
Proper position of all guards and covers + See “12.1.1 WALK-AROUND CHECK”.
l Use safety features such as safety lock levers and the seat belt properly.
l Never remove any safety features. Always keep them in good operating condition.
Safety lock lever + See “12.12 PARKING MACHINE”.
Seat belt + See “12.1.4 USING SEAT BELT”.
l Improper use of safety features could result in serious bodily
injury or death.
1 CLOTHING AND PERSONAL PROTECTIVE ITEMS 1

l Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts
and cause serious injury or death.
l Also, do not wear oily clothes, because they are flammable.
l Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the
machine. Always wear safety goggles, hard hat and heavy gloves if your job involves scattering
metal chips or minute materials particularly when driving pins with a hammer and when cleaning
the air cleaner element with compressed air. Check also that there is no one near the machine.
l Check that all protective equipment functions properly before using.
Cleaning element --) See “24.2 WHEN REQUIRED”.
AE305770
--j UNAUTHORIZED MODIFICATION 1

Any modification made without authorization from Komatsu can create hazards. Before making a
modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or
damage caused by any unauthorized modification.
l-2
g WARNING: Failure to follow these safety precautions may lead
to a serious accident. 6. GENERAL PRECAUTIONS
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT

To prevent an accident caused by touching an unlocked control lever, perform the following before
leaving the operator’s seat.
l Set the gear shift lever to the neutral position, then set the safety lock lever of the gear shift lever
(on the left side of the operator’s seat) to the lock position.
l Press the center of the right-hand and left-hand steering pedals to apply the brake, then set the
safety lock lever of the steering pedals to the lock position.
l Lower the work equipment to the ground, then set the safety lock lever of the work equipment
control lever ton the right side of the operator’s seat) to the lock position.
If the machine starts moving suddenly or moves differently from the operator’s will, it can cause
serious injury or death.
Never jump on or off the machine. Never get on or off a moving machine.
When getting on or off the machine, always face the machine and use the handrails and steps.
Never hold any control levers or lock levers when getting on or off the machine.
To ensure safety, always maintain three-point contact (both feet and one hand, or both hands and
one foot) with the handrails and steps to ensure that you support yourself.
If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Always keep
these parts clean. Repair any damage and tighten any loose bolts.
When getting on or off the machine, or when moving along the top of the track, if you hold the
handrail inside the door when moving on- top of the track shoe, and the door lock is not locked
securely, the door may move and cause you to fall.
Always lock the door securely.
5010 5020
AL187320
l-3
A E;JJ:c1,Gs’, f%;ereasons of safety, always
6. GENERAL PRECAUTIONS ty precautrons.
FIRE PREVENTION FOR FUEL AND OIL

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly flammable and can be
hazardous.
Always observe the following:
l Keep any flame or lighted cigarette away from flammable fluids.
l Stop the engine and do not smoke when refueling.
l Tighten all fuel and oil caps securely.
l Use well-ventilated areas for adding or storing oil and fuel.
l Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
A0055020 A0055030 A0055040
Immediately after operations are stopped, the engine oil and hydraulic oil are at high temperature
and are still under pressure. Attempting to remove the cap, drain the oil or water, or replace the filters
may lead to serious burns. Always wait for the temperature to go down, and follow the specified
procedures when carrying out these operations.
To prevent hot water from spurting out, stop the engine, wait for the water to cool, then loosen
the cap slowly to relieve the pressure before removing the cap.
(When checking if the water temperature has gone down, put your hand near the front face of the
radiator and check the air temperature. Be careful not to touch the radiator.)
To prevent hot oil from spurting out, stop the engine, wait for the oil to cool, then loosen the cap
slowly to relieve the pressure before removing the cap.
(When checking if the oil temperature has gone down, put your hand near the front face of the
hydraulic tank and check the air temperature. Be careful not to touch the hydraulic tank.)
1-4
A WARNING: Failure to follow these safety precautions may lead
to a serious accident. 6. GENERAL PRECAUTIONS
Asbestos dust can be hazardous to your health if it is inhaled.

Komatsu does not use asbestos in its products, but if you handle materials containingasbestos
fibers, follow the guidelines given below:
Never use compressed air for cleaning.
Use water to keep down the dust when cleaning.
If there is danger that there may be asbestos dust in the air, operate the machine from an upwind
position whenever possible.
Use an approved respirator if necessary.
1 CRUSHING OR CUTTING PREVENTION 1

Do not enter, or put your hand or arm or any other part of your body between movable parts such
as the work equipment and cylinders, or between the machine and work equipment.
If the work equipment is operated, the clearance will change and this may lead to serious damage
or personal injury.
If it is necessary to go between movable parts, always lock the levers and be sure that the work
equipment cannot move. For details, see “PRECAUTIONS DURING MAINTENANCE”.
FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur.
Be sure that fire extinguishers have been provided and read the labels to ensure that you know
how to use them.
Provide a first aid kit at the storage point. Carry out periodic checks and add to the contents if
necessary.
Know what to do in the event of a fire or injury.
Decide the phone numbers of persons (doctor, ambulance, fire station, etc.) to contact in case of
an emergency. Post these contact numbers in specified places and make sure that all personnel
know the numbers and correct contact procedures.
Location of fire extinguisher, first aid box +
See “26. INSTALLATION OF FIRE EXTINGUISHER”.
A WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.
ROPS
If ROPS is installed, do not operate the machine with the ROPS removed.
ROPS is installed to protect the operator if the machine should roll over. It supports the load when
the machine rolls over and also absorbs impact energy. The Komatsu ROPS fulfills all worldwide
regulations and standards, but it is damaged by falling objects or by rolling over, its strength will
be reduced and it will not be able to provide its original capacity.
In such a case, please contact your Komatsu distributor for advice on the method of repair. Even if
ROPS is installed, it can only protect you properly if you wear the seat belt.
Always fasten the seat belt when operating the machine.
Seat belt + See “12.1.4. USING SEAT BELT”.
PRECAUTIONS FOR AlTACHMENTS

l When installing and using an optional attachment, read the instruction manual for the attachment
and the information related to attachments in this manual.
l Do not use optional parts or attachments that are not authorized by Komatsu or your Komatsu
distributor. Use of unauthorized attachments could create a safety problem and adversely affect
the proper operation and useful life of the machine.
l Any injury, accidents, product failures resulting from the use of unauthorized attachments will not
be the responsibility of Komatsu.
PRECAUTIONS WITH SEAT BELT

l To ensure safety during operations, always wear the seat belt.
l Before fastening the seat belt, check that there is no abnormality in the belt or belt mount bracket.
If these are worn or damaged, replace the seat belt.
l Be sure that the seat belt is not twisted when fastening it.
Seat belt + See “12.1.4 USING SEAT BELT”.
VENTILATION FOR E
Exhaust fumes from the engine can kill.
l If it is necessary to start the engine within an enclosed area, or you handle fuel, flushing oil, or
paint, open the doors and windows to ensure that you provide adequate ventilation to prevent
gas poisoning.
l If opening the doors and windows still does not provide adequate ventilation, set up fans.
A0055060
I
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7. PRECAUTIONS DURING A WARNING: Failure to follow these safety
OPERATION precautions may lead to a serious accident.
7.1 BEFORE STARTING ENGINE
Before starting operations, thoroughly check the area for any unusual conditions that could be
dangerous.
Check the terrain and condition of the ground at the worksite, and determine the best and safest
method of operation.
Make the ground surface as hard and horizontal as possible before carrying out operations.
If the jobsite is dusty, spray water before starting operations.
If you need to operate on a road, protect pedestrians and cars by designating a person for worksite
traffic duty or by installing fences and putting up No Entry signs around the worksite.
If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact
each utility and identify their locations. Be careful not to sever or damage any of these lines.
Check the ground condition and the depth and flow of water before operating in water or crossing
a river. NEVER be in water which is in excess of the permissible water depth.
Permissible water depth -I See “12.9 PRECAUTIONS FOR OPERATION”.
AE205030
CHECKS BEFORE STARTING ENGINE

Carry out the following checks before starting the engine at the beginning of the days work.
Failure to carry out these checks may lead to serious injury or damage.
Completely remove all flammable materials accumulated around the engine and battery, return
all fuel containers to their proper place, remove all parts and tools from the operator’s compart-
ment, and remove any dirt from the mirrors, handrails, and steps.
Walk-around checks + See “12.1.1 WALK-AROUND CHECK”.
Check the coolant level, fuel level, and oil level in the hydraulic tank, check for clogging of the air
cleaner, and check the electric wiring.
Checks before starting + See “12.1.2 CHECK BEFORE STARTING”.
Adjust the operator’s seat to a position where it is easy to carry out operations, and check for wear
or damage to the seat belt and seat belt mounting equipment.
Adjusting operator’s seat + See “12.1.3 ADJUST OPERATOR’S SEAT”.
Check that the gauges work properly, and check that the control levers are all at the NEUTRAL
position.
Method of checking operation of gauges +
See “12.1.5 OPERATIONS AND CHECKS BEFORE STARTING ENGINE”.
the above inspections show any abnormality, carry out repairs immediately.
A0055020
l-7
A WARNING: For reasons of safety, always
7. PRECAUTIONS DURING OPERATION follow these safety precautions.
l Do not place parts or tools around the operator’s seat. They could break lever or a switch or can
cause an accident. Place them in the tool box in the engine room (on the right side).
l If mud, oil, snow, etc. stick to the floor, levers, handrails, steps, etc., you may slip on them. Wipe
them off well.
l Before fastening the seal belt, confirm that it and its fittings are free from damage and wear.
- PRECAUTIONS FOR LOCKING WINDOW GLASS AT MAINTENANCE

POSITION (MACHINES WITH CAB)
The window glass can be locked at an intermediate position to prevent it from chattering.
Even if it is locked, it may move them the machine is started or stopped sharply.
Do not put your head, hands, or body outside the window when the machine is working or moving.
l-8
g ~A$4~G; Faz;zo follow these safety precautions may lead
7. PRECAUTIONS DURING OPERATION
WHEN OPERATING THE ENGINE INDOORS, VENTILATE THE WORKING PLACE WELL
The exhaust gas from the engine is dangerous.
l When starting the engine in a room or confined space, open
the windows and doors for ventilation.
A0055060
PRECAUTIONS FOR USE OF MIRRORS (OPTIONAL), WINDOW GLASS

(MACHINE WITH CAB) AND LIGHTS
l Clean the window glass and lights to keep visibility high.
l Adjust the position of the rear view mirrors so that you can see them most easily from the
operator’s seat, and clean their surfaces.
If any of them is broken, replace it.
l Confirm that headlamps and rear lamps suitable for the work are installed, and that they can be
turned on and off normally.
INSPECTION OF MACHINE
Before starting the engine, adjust the operator’s seat so that you can operate in a easy position.
If the operator’s seat is not adjusted correctly, you may make a mistake in operation or be fatigued,
and that can cause accidents.
Adjust the operator’s seat so that you can operate the control levers and pedals fully with your
back fitted to the seat back.
Adjustment of operator’s seat + See “12.1.3 ADJUSTMENT OF OPERATORS SEAT”.
Before starting the engine, confirm that the safety lock lever is at the LOCK position.
Before starting the engine, be sure to perform a “Walk-around
check”, “Check before starting” and “Operation and check be-
fore starting engine”
Walk-around check + See “13.1.1 WALK-AROUND CHECK”.
Check before starting +
See “12.1.2 CHECK BEFORE STARTING”.
Operation and check before starting engine +
See “12.1.4 OPERATION AND CHECK BEFORE STARTING”.
Confirm by the above checks that the machine is free from trouble.
If trouble is found and it cannot be repaired, be sure to but a
warning tag on the work equipment lever.
Lock
Free
A0142136
l-9
& :;I;;/& Fooeeasons of safety, always
7. PRECAUTIONS DURING OPERATION y precautions.
7.2 AFTER STARTING ENGINE

WHEN STARTING ENGINE
Walk around your machine again just before mounting it, and check for people and objects that
1
might be in the way.
Never start the engine if a warning tag has been attached to the’blade control lever.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
An additional worker may ride in the machine only when sitting in the passenger seat. Do not allow
anyone to ride on the machine body.
If the backup alarm is installed, confirm that the alarm operates normally.
DO NOT operate
When this plate is not being used
keep it in the storage compartment.
09963-03000 d
CHECKS AFTER STARTING ENGINE

Failure to carry out the checks properly after starting the engine will lead to delays in discovery of
abnormalities, and this may lead to serious injury or damage to the machine.
When carrying out the checks, use a wide area where there are no obstructions. Do not allow anyone
near the machine.
l Check the operation of the gauges and equipment, and check the operation of the blade, ripper,
brakes, travel system, and steering system.
l Checks for any abnormality in the sound of the machine, vibration, heat, smell, or gauges; check
also that there is no leakage of air, oil, or fuel.
l If any abnormality is found, carry out repairs immediately.
If the machine is used when it is not improper condition, it may lead to serious injury or damage
to the machine.
PRECAUTIONS WHEN STARTING OFF

Before starting off, check again that there is no one in the surrounding area and that there is no
obstacles.
When starting off, sound the horn as an alert.
Always operate the machine only when seated.
An additional worker may ride in the machine only when sitting in the passenger seat. Do not allow
anyone to ride on the machine body.
Check that the backup alarm works properly.
Always close the door of the operator’s compartment and check that the door is securely locked.
AE305600
I-IO
g g;;F.l;If; E;zzc follow these safety precautions may lead
4 CHECK WHEN CHANGING DIRECTION 1

To prevent serious injury or death, always do the following before moving the machine or doing the
leveling work.
Before changing between forward and reverse, reduce speed and stop the machine.
Before operating the machine, sound the horn to warn people in the area.
Check that there is no one near the machine. Be particularly careful to check behind the machine.
When operating in areas that may be hazardous or have poor visibility, designate a person to direct
worksite traffic.
Ensure that no unauthorized person can come within the direction of turning or direction of travel.
Always be sure to carry out the above precautions even when the machine is equipped with a
backup alarm and mirrors.
Appoint a ground guide, when necessary, particularly when driving in reverse.
*
A0055080
PRECAUTIONS WHEN TRAVELING

It is dangerous to look around you when operating. Always concentrate on your work.
It is dangerous to drive too fast, or to start suddenly, stop suddenly, turn sharply, or zigzag.
If you find any abnormality in the machine during operation (noise, vibration, smell, incorrect
gauges, air leakage, oil leakage, etc.), move the machine immediately to a safe place and look for
the cause.
Do not operate the steering suddenly. The work equipment may hit the ground surface and cause
the machine to lose its balance, or may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid sudden changes in direction.
Avoid traveling over obstacles as far as possible. If the machine has to travel over an obstacle,
keep the work equipment as close to the ground as possible and travel at low speed. Never travel
over obstacles which make the machine tilt strongly (IO” or more).
When traveling or carrying out operations, always keep your distance from other machines or
structures to avoid coming into contact with them.
I-II
a ;;zJ;l& Po;ereasons of safety, always
7. PRECAUTIONS DURING OPERATION ty precautrons.
TRAVELING ON SLOPES
Traveling on slopes could result in the machine tipping over or slipping to the side.
When traveling on slopes, keep the blade approximately 20 to 30 cm above the ground. In case
of emergency, quickly lower the blade to the ground to help the machine to stop.
Do not turn on slopes or travel across slopes. Always go down to a flat place to perform these
operations.
Do not travel on grass, fallen leaves, or wet steel plates. Even slight slopes may cause the machine
to slip to the side, so travel at low speed and make sure that the machine is always traveling
directly up or down the slope.
When traveling downhill, use the braking force of the engine and travel slowly.
Be careful when allowing the machine to travel downhill under its own weight. It may steer in the
opposite direction.
Reverse steering when traveling downhill *
See “12.72 TURNING WHILE DESCENDING A SLOPE”.
ADO51 690
-j’ SECURING ENOUGH VISIBILITY 1

l When working in a dark place, turn on the head lamp and rear lamp of the machine, and use
additional lighting equipment, if necessary.
l If visibility is lowered by fog, snow, rain, etc., stop working and wait until sufficient visibility for
the work is restored.
OPERATE CAREFULLY ON SNOW

When working on snow or icy roads, even a slight slope may cause the machine to slip to the side,
so always travel at low speed and avoid sudden starting, stopping, or turning. There is danger
of slipping particularly on uphill or downhill slopes.
With frozen road surfaces, the ground becomes soft when the temperature rises, so the travel
conditions become unstable. In such cases be extremely careful when traveling.
When there has been heavy snow, the road shoulder and objects placed beside the road are buried
in the snow and cannot be seen, so always carry out operations carefully.
When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and
use the engine as a brake while applying the foot brake intermittently (depress the brake
intermittently several times). If necessary, lower the blade to the ground to stop the machine.
The load varies greatly according to the characteristics of the snow, so adjust the load accordingly
and be careful not to let the machine slip.
1-12
g ;V;;;;Gs Fai;ai~~ follow these safety precautions may lead
I
Do not operate the machine on soft ground. It is difficult to get the machine out again.
Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these
areas collapse under the mass or vibration of your machine, it could fall or tip over and this could
result in serious injury or death. Remember that the soil after heavy rain, blasting, or earthquakes
is weakened in these areas.
Earth laid on the ground and the soil near ditches is loose. It can collapse under the mass or
vibration of your machine and cause your machine to tip over.
Install the head guard (FOPS) when working in areas where there is danger of falling stones.
Install the ROPS and wear the seat belt when working in areas where there is danger of falling
rocks or of the machine turning over.
PARKING MACHINE
Park the machine on level ground where there is no danger of -falling rocks or landslides, or of
flooding if the land is low, and lower the work equipment to the ground.
If it is necessary to park the machine on a slope, set blocks under the tracks to prevent the machine
from moving, then dig the work equipment into the ground.
After stopping the engine, operate the blade control lever several times to the RAISE and LOWER
positions to release the remaining pressure in the hydraulic circuit.
When parking on public roads, provide fences, signs, flags, or lights, and put up any other
necessary signs to ensure that passing traffic can see the machine clearly, and park the machine
so that the machine, flags, and fences do not obstruct traffic.
Parking procedure + See “12.12 PARKING MACHINE”.
When leaving the machine, lower the work equipment completely to the ground, place the joystick
to the neutral position, and the blade and ripper control levers to the HOLD position. Then set the
safety lock lever and parking brake lever to the LOCK position, stop the engine, and use the key
to lock all the equipment. Always remove the key and take it with you.
Work equipment posture + See “12.12 PARKING MACHINE”.
Always close the door of the operator’s compartment.
Lock
Free
AD142136
1-13
4 PRECAUTIONS IN COLD AREAS 1

After completing operations, remove all water, snow, or mud stuck to the wiring harness,
connector 0, switches, or sensors, and cover these parts.
If the water freezes, it will cause malfunctions of the machine when it is next used, which may
lead to unexpected accidents.
Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up
before the control levers are operated, the reaction of the machine will be slow, and this may lead
to unexpected accidents.
Operate the control levers to relieve the hydraulic pressure (raise to above the set pressure for
the hydraulic circuit and release the oil to the hydraulic tank) to warm up the oil in the hydraulic
circuit. This ensures good response from the machine and prevents malfunctions.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different
power source. There is danger that this will ignite the battery.
When charging or starting the engine with a different power source, melt the battery electrolyte
and check for leakage of battery electrolyte before starting.
Battery charge rate + See “14. COLD WEATHER OPERATION”.
/ AE305820
1-14
A WARNING: Failure to follow these safety precautions may lead
to a serious accident. 7. PRECAUTIONS DURING OPERATION
7.3 TRANSPORTATION
LOADING AND UNLOADING
Loading and unloading the machine .always involves potential hazards. EXTREME CAUTION
SHOULD BE USED.
When loading or unloading the machine, run the engine at low idling and travel at low speed.
Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge
of a road.
ALWAYS use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough
to provide a safe loading slope. Place blocks under both ramps to support them before loading
and unloading.
When unloading on to an embankment or temporan/ structure, make sure that it has ample width,
strength, and grade.
To prevent the machine from slipping, be sure that the ramp surface is clean and free of grease,
oil, ice and loose materials. Remove mud from the machine tracks.
NEVER correct your steering on the ramps. If necessary, drive away from the ramps and climb
again.
After loading, block the machine tracks and secure the machine with tie-downs.
Loading and unloading * See “13. TRANSPORTATION”.
Tie-downs + See “13. TRANSPORTATION”.
Ra
Distance between ramps AE50648B
When shipping the machine on a hauling vehicle, obey all state and local laws governing the
weight, width, and length of a load. Also obey all applicable traffic regulations.
Take into account the width, height and weight of the load when determining the shipping route.
Height, width, load of machine -I See “13.4 PRECAUTIONS FOR TRANSPORTATION”.
When passing over bridges or structures on private land, check first that the structure is strong
enough to support the mass of the machine. When traveling on public roads, check first with the
relevant authorities and follow their instructions.
On machines equipped with a cab, always lock the door securely.
1-15
A ;f!/;;ze Fcxeasons of safety, always
7. PRECAUTIONS DURING OPERATION y precautrons.
7.4 BATTERY
BAlTERY HAZARD PREVENTION
Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, so mistaken
handling can lead to serious injury or fire. For this reason, always observe the following precautions.
Never bring any lighted cigarette or flame near the battery.
When working with batteries, ALWAYS wear safety glasses and rubber gloves.
If you spill acid on your clothes or skin, immediately flush the area with large amounts of water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into your eyes, flush them
immediately with large quantities of water and see a doctor at once.
If you accidentally drink electrolyte, drink a large quantity of water or milk, beaten egg or vegetable
oil. Call a doctor or poison prevention center immediately.
Before working with batteries, stop the engine and turn the starting switch to the OFF position.
Avoid short-circuiting the battery terminals (between the positive @ terminal and negative 0
terminal) through accidental contact with metal objects, such as tools.
When installing the battery, connect the positive @terminal first, and when removing the battery,
disconnect the negative @ terminal (ground side) first.
When removing or installing, check which is the positive @ terminal and negative 0 terminal, and
tighten the nuts securely.
If the battery electrolyte is near the LOWER LEVEL, add distilled water. Do not add distilled water
above the UPPER LEVEL.
When cleaning the top surface of the battery, wipe it with a damp cloth. Never use gasoline,
thinner, or any other organic solvent or cleaning agent.
Tighten the battery caps securely.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different
power source. There is danger that this will ignite the battery.
When charging or starting the engine with a different power source, melt the battery electrolyte
and check for leakage of battery electrolyte before starting.
Always remove the battery from the chassis before charging it.
A0055110
1-16
A ~~~f$Gi; E$rrr$ follow these safety precautions may lead
STARTING WITH BOOSTER CABLES

If any mistake is made in the method of connecting the booster cables, it may cause a fire, so always
do as follows.
Carry out the starting operation with two workers (with one worker sitting in the operator’s seat).
When starting from another machine, do not allow the two machines to touch.
When connecting the booster cables, turn the starting switch OFF for both the normal machine
and problem machine.
Be sure to connect the positive @ cable first when installing the booster cables. Disconnect the
ground or negative @ cable first when removing them.
The final ground connection is the connection of the ground to the engine block of the problem
machine. However, this will cause sparks, so be sure to connect it as far as possible from the
battery.
Starting procedure when using booster cables + See “16.2 IF BATTERY IS DISCHARGED”.
When removing the booster cables, be careful not to let the booster cable clips touch each other
or to let the clips touch the machine.
INCORRECT
w A0067320
If the battery is handled incorrectly when it is being charged, there is danger that the battery may
explode, so follow the instructions in HANDLING BATTERY and in the instruction manual for the
charger, and always observe the following precautions.
Carry out the charging in a well-ventilated place, and remove the battery caps. This disperses the
hydrogen gas and prevents explosion.
Set the voltage on the charger to match the voltage on the battery to be charged. If the voltage
setting is wrong, it will cause the charger to overheat and catch fire, and this may lead to an
explosion.
Connect the positive @ charging clip of the charger to the positive @terminal of the battery, then
connect the negative 0 charging clip to the negative 0 terminal of the battery. Be sure to tighten
both terminals securely.
If the battery charge is less than l/IO of the rated charge, and high speed charging is carried out,
set to a value below the rated capacity of the battery.
If there is an excessive flow of charging current, it may cause leakage or evaporation of the
electrolyte, which may catch fire and explode.
INCORRECT
A0055110
1-17
a WARNING: For reasons of safety, always
7. PRECAUTIONS DURING OPERATION follow these safety precautions.
7.5 TOWING
-I WHEN TOWING 1
Injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in
the selection of the wire rope, so always do as follows.
Do not tow in a different way from the method given in the section METHOD OF TOWING.
Always wear leather gloves when handling wire rope.
When carrying out the preparation for towing with another worker, agree on signals before
starting the operation.
If the engine on the problem machine will not start or there is a failure in the brake system, please
contact your Komatsu distributor for repairs.
It is dangerous to tow a machine on a slope, so choose a place where there is a gradual slope.
If there is no place with a gradual slope, carry out work to make the slope as small as possible.
If a problem machine is towed by another machine, ALWAYS use a wire rope with a sufficient
towing capacity for the weight of the problem machine.
Do not use a wire rope which has cut strands @, kinks @, or reduced diameter 0.
1-18
8. PRECAUTIONS FOR a WARNING: Failure to follow these safety
MAINTENANCE precautions may lead to a serious accident.
8.1 BEFORE CARRYING OUT MAINTENANCE

NOTIFICATION OF FAILURE
Carrying out maintenance not described in the Komatsu operation and maintenance manual may
lead to unexpected failures.
Please contact your Komatsu distributor for repairs.
WARNING TAG
ALWAYS attach the “DO NOT OPERATE” warning tag to the blade control lever in the operator’s
cab to alert others that you are working on the machine. Attach additional warning tags around
the machine if necessary.
If others start the engine, or touch or operate the blade control lever while you are performing
service or maintenance, you could suffer serious injury or death.
Warning tag Part No. 09963-03000
DO NOT operate
When this plate is not being used
keep it in the storage compartment.
09963.03000
CLEAN BEFORE INSPECTION AND MAINTENANCE 1

Clean the machine before carrying out inspection and maintenance. This will ensure that dirt does
not get into the machine and will also ensure that maintenance can be carried out safely.
If inspection and maintenance are carried out with the machine still dirty, it will be difficult to find
the location of problems, and there is also the danger that you will get dirty or mud in your eyes,
and that you will slip and injure yourself.
When washing the machine, always do as follows.
Wear non-slip shoes to prevent yourself from slipping on the wet surface.
When using high-pressure steam to wash the machine, always wear protective clothing.
This will protect you from being hit by high-pressure water, and cutting your skin or getting mud
or dust into your eyes.
Do not spray water directly on to the electrical system (sensors, connectors) 0. If water gets
into the electrical system, there is danger that it will cause defective operation and malfunction.
AE305620
A0055150
8. PRECAUTIONS FOR MAINTENANCE
KEEP WORK PLACE CLEAN AND TIDY

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other
substances that will cause you to slip. Always keep the work place clean the tidy to enable you to
carry out operations safely.
If the work place is not kept clean and tidy, there is danger that you will trip, slip, or fall over and
injure yourself.
-I APPOINT LEADER WHEN WORKING WITH OTHERS 1

When repairing the machine or when removing and installing the work equipment, appoint a leader
and follow his instructions during the operation.
When working with others, misunderstandings between workers can lead to serious accidents.
RADIATOR WATER LEVEL

When inspecting the radiator water level, stop the engine, and wait for the engine and radiator
to cool down. Check the water level in the sub-tank. Under normal conditions, do not open the
radiator cap.
If there is no sub-tank, or the radiator cap must be removed, always do as follows.
Wait for the radiator water temperature to go down before checking the water level.
(When checking if the water temperature has gone down, put your hand near the engine or
radiator and check the air temperature. Be careful not to touch the radiator or engine.)
Release the internal pressure before removing the radiator cap, and remove the radiator cap
slowly.
A0055050
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND

MAINTENANCE
When carrying out inspection and maintenance, park the machine on level ground where there
is no danger of falling rocks or land slides, or of flooding if the land is low, then lower the work
equipment to the ground and stop the engine.
Operate blade control lever @ several times to the RAISE and LOWER positions to release the
remaining pressure in the hydraulic circuit, then set safety lock lever @ to the LOCK position.
Put blocks under the track to prevent the machine from moving.
The worker carrying out the maintenance should be extremely careful not to touch or get caught
in the moving parts.
HEAT
OFF
\ L
Free
Lock
AE214979 AE214439
I-20
g WARNING: For reasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions.
USE OF LIGHTING
l When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion specifica-
tions.
If such lighting equipment is not used, there is danger of explosion.
l If work is carried out in dark places without installing lighting, there is danger of injury, so always
install proper lighting.
l Even if it is dark, do not use a lighter or flame instead of lighting. There is danger of starting a
fire, and if the battery gas ignites, it may cause an explosion.
l When using the machine as the power supply for the lighting, follow the instructions in this
Operation and Maintenance Manual.
There is danger of the fuel and battery gas catching fire during maintenance, so always follow the
precautions below when cartvinn out maintenance.
Store fuel, oil, grease, and-other flammable materials away from flame.
Use non-flammable materials as the flushing oil for cleaning parts. Do not use diesel oil or
gasoline. There is danger that they will catch fire.
Never smoke when carrying out inspection or maintenance. Always smoke in the prescribed place.
When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion specifica-
tions. Never use lighters or matches as lighting.
When carrying out grinding or welding operations on the chassis, remove any flammable
materials to a safe place.
Be sure that a fire extinguisher is present at the inspection and maintenance point.
1-22
A EAa;;;;G; F;;;e$c follow these safety precautions may lead
8.2 DURING MAINTENANCE

PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel
into the area. If necessary, employ an observer.
Extra precaution should be used when grinding, welding, and using a sledge-hammer.
AlTACHMENTS
Appoint a leader before starting removal or installation operations for attachments.
Do not allow anyone other than the workers close to the machine or attachment.
Place attachments that have been removed from the machine

in a safe place so that they do not fall. Put a fence around the
attachments, and set up No Entry signs to prevent unauthorized
persons from coming close.
WORK UNDER THE MACHINE

Stop the machine on firm, level ground, and always lower all work equipment to the ground before
performing service or repairs under the machine.
0 Always block the track shoes securely.
0 It is extremely dangerous to work under the machine if the track

shoes are off the ground and the machine is supported only by
the work equipment. Never work under the machine if the
machine is poorly supported.
A0055140
WORK ON TOP OF MACHINE

When carrying out maintenance on top of the machine, make sure that the footholds are clean
and free of obstructions, and follow the precautions below to prevent yourself from falling.
l Do not spill oil or grease.
l Do not leave tools lying around.
l Mind your step when you are walking.
Never jump down from the machine. When getting on or off the machine, always use the steps
and handrails, and maintain three-point contact (both feet and one hand or both hands and one
foot) at all times.
Use protective equipment if necessary.
1-23
A $Y~;;;ize Fo%eeasons qf safety, always
8. PRECAUTIONS FOR MAINTENANCE y precautions.
When carrying out maintenance with the inspection cover open, lock it securely with a lock bar.
If maintenance is carried out with the inspection cover open and not locked in position, it may close
suddenly if knocked or blown by the wind, and may cause injury to the operator.
MAINTENANCE WITH ENGINE RUNNING

To prevent injury, do not carry out maintenance with the engine running. If maintenance must be
carried out with the engine running, carry out the operation with at least two workers and do as
follows.
One worker must always sit in the operator’s seat and be ready to stop the engine at any time.
All workers must maintain contact with the other workers.
When carrying out operations near rotating parts, there is danger of being caught in the parts, so
be extremely careful.
When cleaning inside the radiator, set safety lock lever @ to the LOCK position to prevent the work
equipment from moving.
Do not touch any control levers. If any control lever must be operated, always give a signal to the
other workers to warn them to move to a safe place.
Never touch the fan blade or fan belt with any tool or any part of your body. There is danger of
serious injury.
Lock
Free
A0055210
AD142138
d DO NOT DROP TOOLS OR PARTS INSIDE MACHINE 1

l When opening the inspection window or tank oil filler to carry out inspection, be careful not to
drop any nuts, bolts, or tools inside the machine.
If such parts are dropped into the machine, it will cause breakage of the machine, mistaken
operation, and other failures. If you drop any part into the machine, always be sure to remove it
from the machine.
l When carrying out inspection, do not carry any unnecessary tools or parts in your pocket.
PRECAUTIONS WHEN USING HAMMER 1
1
I I
When using a hammer, always wear safety glasses, safety helmet,

and other protective clothing, and put a brass bar between the
hammer and the part being hammered.
If hard metal parts such as pins, edges, teeth, or bearings are hit
with a hammer, there is danger that broken pieces might fly into
your eyes and cause injury.
AE305880
l-24
g WARNING: Failure to follow these safety precautions may lead
to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE
Welding operations must always be carried out by a qualified welder and in a place equipped with
a proper equipment. Gas is generated, and there is danger of fire or electrocution when carrying out
welding, so never allow any unqualified personnel to carry out welding.
The qualified welder must follow the precautions given below.
Disconnect the battery terminals to prevent explosion of the battery.
Remove the paint from the place being welded to prevent gas from being generated.
If hydraulic equipment or piping, or places close to these are heated, flammable vapor or spray
will be generated, and there is danger of this catching fire, so avoid applying heat to such places.
If heat is applied directly to rubber hoses or piping under pressure, they may suddenly burst, so
cover them with fireproof sheeting.
Always wear protective clothing.
Ensure that there is good ventilation.
Clear up any flammable materials, and make sure that there is a fire extinguisher at the workplace.
-j PRECAUTIONS WITH BATTERY 1

When repairing the electrical system or when carrying out electrical welding, remove the negative
(4 terminal of the battery to stop the flow of current.
Handling battery + See “16.2 IF BAlTERY IS DISCHARGED”.
-I WHEN ABNORMALITY IS LOCATED 1

l If any abnormality is found during inspection, always carry out repairs. In particular, if the machine
is used when there is any abnormality in the brakes or work equipment systems, it may lead to
serious accident.
l Depending on the type of failure, please contact your Komatsu distributor for repairs.
RULES TO FOLLOW WHEN ADDING FUEL OR OIL

If any flame is brought close to fuel or oil, there is danger that it will catch fire, so always follow the
precautions below.
l Stop the engine when adding fuel or oil.
l Do not smoke.
l Spilled fuel and oil may cause you to slip, so always wipe it up immediately.
l Always tighten the cap of the fuel and oil fillers securely.
l Always add fuel and oil in a well-ventilated place.
A0055020 A0055030 A0055040
l-25
A ~~VJ~~~;e f%;ereasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE ty precautions.
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO

ADJUST TRACK TENSION
Grease is pumped into the track tension adjustment system under high pressure.
If the specified procedure for maintenance is not followed when making adjustment, valve @ may
fly out and cause damage or personal injury.
When loosening grease drain valve 0, never loosen it more than one turn.
Never put your face, hands, feet, or any other part of your body directly in front of any grease
drain valve.
Adjusting track tension -) See “24.2 WHEN REQUIRED”.
AM143090 A0055200
1
HANDLING HIGH-PRESSURE HOSES
If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may
lead to personal injury or damage. If any damaged hoses or loose bolts are found, stop work and
contact your Komatsu distributor for repairs.
Replacing high-pressure hoses requires a high level of skill, and the torque is determined
according to the type of hose and size, so please do not carry out replacement yourself. Ask your
Komatsu distributor to carry out replacement.
-I PRECAUTIONS WITH HIGH-PRESSURE OIL 1

I
I
When inspecting or replacing high-pressure piping or hoses, always check that the pressure in the
hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious injury
or damage, so always do as follows.
For details of the method of releasing the pressure, see 8.1 BEFORE MAINTENANCE, STOP
ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE. Never carry out inspection
or replacement before releasing the pressure completely.
Wear safety glasses and leather gloves.
If there is any leakage from the piping or hoses, the piping, hoses, and the surrounding area will
be wet, so check for cracks in the piping and hoses and for swelling in the hoses.
If it is difficult to locate the leakage, always please contact your Komatsu distributor for repairs.
If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
lNCORREgp CORREC;_
A0055180 A0055190
l-26
A ;/P$J;;C; Faaililzo follow these safety precautions may lead
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT

HIGH TEMPERATURE
Immediately after stopping operations, the engine coolant, oil at all parts, the exhaust manifold, and
the muffler are at high temperature.
In this condition, if the cap is removed, or the oil is drained, or the filters are replaced, this may result
in burns or other injury. Wait for the temperature to go down, then carry out the inspection and
maintenance in accordance with the procedures given in this manual.
Cleaning inside of cooling system + See “24.2 WHEN REQUIRED”.
Checking coolant level, oil level in hydraulic tank + see “24.3 CHECK BEFORE STARTING”.
Checking lubricating oil level, adding oil + see “24.3 CHECK BEFORE STARTING”.
Changing oil, replacing filters + see “24.4 PERIODIC MAINTENANCE”.
A0055050
1 CHECKS AFTER INSPECTION AND MAINTENANCE 1

Failure to carry out inspection and maintenance fully, or failure to check the function of various
maintenance locations may cause unexpected problems and may even lead to personal injury or
damage, so always do as follows.
Checks when engine is stopped
l Have all the inspection and maintenance locations been checked?
l Have all the inspection and maintenance items been carried out correctly?
l Have any tools or parts dropped inside the machine? It is particularly dangerous if they get
caught in the lever linkage.
l Has water and oil leakage been repaired? Have bolts been tightened?
Checks when engine is running

For details of checks when the engine is running, see “8.2 DURING MAINTENANCE, MAINTE-
NANCE WITH ENGINE RUNNING”, and be extremely careful to ensure safety.
Do the inspection and maintenance locations work normally?
Is there any oil leakage when the engine speed is raised and load is applied to the hydraulic
I
0
system?
I
To prevent pollution, particularly in places where people or animals are living, always follow the
procedures given below.
Never dump waste oil in a sewer system, rivers, etc.
INCORRECT
Always put oil drained from your machine in containers. Never
drain oil directly onto the ground.
Obey appropriate laws and regulations when disposing of

harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
1-27
9. POSITION FOR ATTACHING SAFETY LABELS
Always keep these labels clean. If they are lost or damage,

attaching them again or replace them with a new label.
There are other labels in addition to the safety labels listed as
follows, so handle them in the same way.
Safety labels may be available in languages other than English.
To find out what labels are available, contact your Komatsu
distributor.
9.1 POSITION FOR AlTACHING SAFETY LABELS
AD216850 \ AD21 6660
AE216670
l-28
9. POSITION FOR ATTACHING SAFETY LABELS
1. Cautions for checking engine room 5. Warnings for leaving operator’s seat
(09667-03000) (09654-03000)
WHILE ENGINE IS RUNNING: OBSERVE THE FOLLOWING CAUTIONS

WHEN STARTING THE MACHINE OR WHEN
1. DO NOT OPEN COVER. YOU LEAVE OPERATOR’S SEAT AFTER
PARKING THE MACHINE:
2. KEEP AWAY FROM FAN AND 1. SET THE GEARbHlti LEVER INTO NEU-
FAN-BELT. TRAL POSITION AND LOCK IT WITH TH5
SAFETY LEVER WHEN APPLICABLE.
09667-03000 -
2. LOCK THE BRAKES.
3. LOWER THE WORKING EQUIPMENT TO
THE GROUND AND LOCK THE LEVER.
2. Warnings for opening radiator cap
09654-03000 -
(09668-03000)
6. Cautions before operating machine

(09651-03000)
DO NOT LOOSEN CAP WHEN
WATER TEMPERATURE IS HIGH.
IF LOOSENED, BOILING WATER
MAY GUSH OUT BECAUSE OF
HIGH INTERNAL PRESSURE. BEFORE OPERATING MACHINE,
09668-03000 - READ OPERATION MMANUAL
CAREFULLY.
3. Cautions for inspection and maintenance
(09173-03000) -.
7. Cuations for opening hydraulic tank cap
(09653-03000)
WHEN CARRYING OUT MAINTE-

NANCE.
1. PARK THE MACHINE ON LEVEL
ALWAYS STOP ENGINE WHEN RE-
GROUND.
MOVING CAP.
2. LOWER WORK EQUIPMENTTOTHE
DO NOT LOOSEN CAP i’/HiN OIL
GROUND, AND LOCK THE LEVER. TEMPERATURE IS HIGH. IF LOOS-
3. DO NOT GO UNDER MACHINE ENED, OIL MAY GUSH OUT.
WHEN IT IS RAISED BY THE WORK
SLOWLY OPEN HYDRULIC OIL
EQUIPMENT. TANK CAP AND RELEASE INTER-
09173-03000 - NAL PRESSURE COMPLETELY.
DO NOT OPEN DRAIN PLUG WHEN
OIL TEMPERATURE IS HIGH.
4. Warnings for adjusting track tension
, 09653-03000 -
(09657-03010)
1. TO INCREASE TRACK TENSION. PUMP IN

GREASE THROUGH LUBRICATOR.
2. TO SLACKEN IT. RELEASE GREASE BY
ROTATING LUBRICATION ONE TURN. (FOR
TRACK ADJUSTMENT PROCEDURE, READ
OPERATION AND MAINTENANCE
MANUAL.)
3. DO NOT LOOSEN LUBRICATOR MORE
THAN ONE FULL TURN, ALSO BE CARE-
FUL NOT TO LOOSEN ANY PARTS OTHER
THAN LUBRICATOR. SINCE THE GREASE
IS UNDER HIGH PRESSURE EXCESS LOOS-
ENING IS HIGHLY DANGEROUS.
4. RETIGHTEN LUBRICATOR SECURELY AF-
TER ADJUSTMENT.
09657-03010 -
l-29
9. POSITION FOR AlTACHING SAFETY LABELS
8. Precautions for use of safety devices of lift

arm
(09658-30082)
WHEN USING A STAY;

1. DO NOT CAUSE DAMAGE T
PISTON ROD WITH THE
STAY.
2. DO NOT POSITION THE
BUCKET CONTROL LEVER A
“LOWER”.
09658-30082
9. Precautions for maintenance of engine

(125-98-31131)
I-30
0
2
10. GENERAL VIEW
10.1 GENERAL VIEW OF MACHINE

If directions
are indicated in this section, they refer to the directions shown by the arrows in the
diaaram below.
Bucket
da Dump cylinder
I ift CYI inder
ocket
0 Left
Truck’shoe Idler Truck frame
AD141956
2-2
IO. GENERALVIEW
10.2 GENERAL VIEW OF CONTROLS AND GAUGES
Fu el control lever Inching Pedal Steering Pedal
Gear shift
Safe tv lock lever

(for gear shift lever)
Safety lock lever

/ (for bucket control lever)
Brake lock lever ADZlSOOB
Front wiper Front work I amp

Pilot IamP
Engine oil pressure sw’tch\ Front work
warning IamD /
lamp
Rear wiper 7;;; work /
switch \ \
\\\ I/
button
Ena i n e water \Startina switch

t emne rature
Lamp switch
gauge
I
/ I ./ I \
Torque converter Cigarette Room lamp Rear work lamp
Dust indicator I iahter switch Pilot lamp
oil temperature
gauge AD141978 ADl419BB
2-3
1.1. .-EXPLANATION OF COMPONENTS
The following is an explanation of the devices needed for

operating the machine.
To carry out suitable operations correctly and safely, it is impor-
tant to understand fully the methods of operating the equipment and
the meanings of the displays.
11.1 METERS AND LAMPS
AM141990
1. ENGINE WATER TEMPERATURE GAUGE

This gauge indicates the cooling water temperature.
When the indicator is in the green range during operation, the
water temperature is normal.
If the indicator moves from the green range into the red range
during operation, stop the machine and run the engine with no load
at medium speed until the water temperature goes down.
After starting the engine, warm up it until the indicator moves AC1214380
into the green range.
2. TORQUE CONVERTER OIL TEMPERATURE GAUGE

This gauge indicates the torque converter oil temperature.
When the indicator is in the green range during operation, the
oil temperature is normal.
If the indicator moves from the green range into the red range
during operation, stop the machine and run the engine with no load
at medium speed until the oil temperature goes down. AM086070
2-4
11. EXPLANATION OF COMPONENTS
3. SERVICE METER
This meter shows the total operation hours of the machine.
The service meter advances while the engine is running - even
if the machine is not traveling.
Set the periodic maintenance intervals using this display.
While the engine is running, operation display @ at the top
inside of the meter will rotate to show that the meter is advancing.
Meter @ will advance by 1 for each hour of operation regardless
of the engine speed.
4. CHARGE LAMP
This lamp indicates malfunction of the alternator.
When the starting switch is turned ON, it will light up, but it should
go out when the engine speed rises.
If the lamp lights up during operation, stop the engine and check
the V-belt tension. If any abnormality is found, see “16.3 OTHER
TROUBLE”.
A0120660
5. ENGINE OIL PRESSURE WARNING LAMP

This lamp warns that the engine lubricating oil pressure has
dropped. When the starting switch is turned ON, it will light up.
When the lamp goes off after the engine is started, the oil
pressure is normal.
When the lamp lights up during operation, the oil pressure is
lower.
Immediately stop the engine and look for the cause. For details,
A0120700
see “16.3 OTHER TROUBLE”.
6. GLOW SIGNAL
This indicates the glow plug is red-heated.
When holding the starting switch key at the HEAT position, this
signal glows red after 20 - 30 seconds.
When releasing the key, the key will return to the OFF position l
and the signal will go off.
@
2-5
11.2 SWITCHES
I AM142020
1. STARTING SWITCH
This switch is, used to start or stop the engine.
OFF ( 0 I position
At this position, the starting switch key can be inserted or
removed. When the switch is turned to this position, the electrical
circuits are switched off and the engine stops.
ON 1 I I position
In this position, electric current flows in the charging and lamp
circuits.
.Keep the starting switch key at the ON position while the engine
is running.
START @I position
This is the position to start the engine. Hold the key at this
position while cranking. Release the key immediately after the
engine has been started. The key will return to ON position when
released.
HEAT (@I position

Turn the starting switch key to the HEAT position when starting
in cold weather.
The glow plug is operated while the key is held in the HEAT
position.
When the glow signal is red hot, release the key.
When the key is released, it will return to OFF, so turn it
immediately to the START position to start the engine.
2-6
.,
I ^
2. LAMP SWITCH
This lights up the head lamps, the rear working lamp and the
panel lamp. 2
Position OFF: Lamps go off. 1
Position 1: Head lamps and panel lamp light up.
OFF
Position 2: Rear working lamp lights up in addition to the lamps
in position 1.
ADl4203B
3. HORN BUTTON
To sound the horn, push the button located in front of the R.H.
arm rest.
I AM142040
2-7
11.3 CONTROL LEVERS, PEDALS
1. GEAR SHIFT LEVER

This lever is used to change the gear speed.
The transmission has three forward gears and three reverse
gears, and any of them can be selected by shifting this lever to the
corresponding position.
REMARK
If the gear shift lever is not at N (Neutral) position, the engine
does not start.
AM142060
2. FUEL CONTROL LEVER

This lever is used to adjust the speed and output of the engine.
@ Engine stop: Pull the knob from the low idling position, then
push in forward end.
@ Low idling: Push in the lever to forward (to the knob stopper).
@ Full speed: Pull the knob from position @I to the end.
AM142070
2-8
3. INCHING PEDAL
I
A WARNING
Do not place your foot on this pedal unnecessarily.
This pedal is used to disconnect and connect the engine power

for operating the machine at a little movement. If it is pressed I
halfway, the power is disconnected. If it is further pressed, the brake

AM142080
is applied to stop the machine. !
Use this pedal when’ approaching an object or moving the
machine body little by little during digging work.
4. STEERING PEDAL
A WARNING
Do not place your foot on this pedal unnecessarily.
If the steering pedal in the turning direction is pressed, the

steering clutch is disengaged and the machine turns slowly. If it is
pressed further, the steering brake is turned on the machine per-
AM142090
forms a pivot turn.
If the center between both pedals is pressed, the steering clutch
is engaged and the brake is applied.
BUCKET CONTROL LEVER

This lever is used to control the bucket.
RAISE : (X
HOLD : l-1
Bucket is stopped and held in this position.
LOWER : (4,
FLOAT : (F)
Bucket wili%&e freely according to external force.
AM142100
When released from FLOAT position, this lever will not return to
HOLD position, so it must be moved back by hand.
@ TILT : ($1
@I DUMP : (@-I
@ POSITION
REMARK
If the lever is set to “RAISE” or “POSITION” position, it is
automatically returned to “HOLD” position and the bucket stops
when the bucket returns to the adjustment position of the kick-out
or positioner.
2-9
1I.. EXPLANATION OF COMPONENTS
6. DECELERATlON PEDAL
A WARNING
When the machine climbs to the top of a slope or it dumps soil
from a cliff, the load reduces and the travel speed rises sud-
denly, and that is dangerous. T.o prevent, this, press the
decelerator pedal to lower the travel speed. .s
AM142120
This pedal is used to lower the engine speed from the level set
with the fuel control lever to the low,idling level.
If this pedal is pressed, the engine speed lowers. I. ‘_
7. SAFEN LOCK LEVER (For bucket control lever)
A WARNING I
When leaving the operator’s compartment, set the safety lock
lever securely to the LOCK position. If the control lever is not
locked, and it is touched by mistake, this may lead to a
serious accident.
If the safety lock lever is not placed .securely in the LOCK
position, the control lever may not be properly locked.
When parking or servicing the machine,, be sure to lower the
bucket and set the safety lock in the LOCK position.
This is the locking device of bucket control lever.
LOCK position: Raising, lowering, dumping, and tilting operations

are locked.
FREE position: Raising, lowering, dumping, and tilting operations
can be performed.
2-10
8. BRAKE LOCK LEVER
g WARNING
Whenever machine is parked, lock brake pedal without fail.
This is the locking device of the brake pedal when parking.

When locking the brake, pull the lock lever towards you (place
in the LOCK position), then depress the center of steering, pedal
strongly to apply the lock securely.
When releasing the brake, keep the center of steering pedal
depressed, and push the lock lever.
9. SAFETY LOCK LEVER (For gear shift lever)
When leaving the operator s seat, set the safety lock lever to Free a
the lock Dosition securelv.
*WARN,,7
If the safety lock lever is not in the lock position and someone
touches the gear shift lever by mistake, a serious accident
may occur.
If the safety lock lever is not set the lock position securely, the
gear shift lever may not be locked.
When parking the machine, be sure to set the gear shift lever
to N (Neutral) position, and lock it.
This lever is used to lock the gear shift lever.
2-11
Il. EXPLANATION OF COMPONENTS
11.4 FUSE BOX

NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from

burning out.
If the fuse becomes corroded, or white powder can be seen, or
the fuse is loose in the fuse holder, replace the fuse.
Replace a fuse with another of the same capacity.
11.4.1 REPLACEMENT OF FUSES // \\

1. Remove bolt @ and cover 0, then replace worn-out fuses.
Fuse capacity and circuit name
No Terminal Fuse Circuit name Remarks

symbol capacity
Lamp in instruments
Head lamp
0 L 20A Rear lamp -
Torque converter oil temper-
ature gauge
@ / H / loA 1 Ki:ioner / -
Engine water temperature gauge

o / F I loA I Backup alarm I -
ci AE215010
@ 1 0 1 20A 1 Spare circuit I -
2-12
11.5 DUST INDICATOR I I

This indicator indicates that the air cleaner element is clogged.
If the cleaner element is clogged, the red piston keeps projecting into
transparent part @_ In this case, clean the cleaner element.
After cleaning the cleaner element, press button @ of the indi- 0
cator to return the red piston to the original position.
II \\
Al4142270
\
Q
a’
ADO52091
11.6 POWER PICKUP CONNECTOR
NOTICE
l Do not use this connector as a power source for a 12 V device.
If it is used, the connected device will be broken.
l Do not connect a device which consumes more power than
480W (24 V x 20 A) [I20 W (12 V x 10 A) in case of a cigarette
lighter] to this connector.
Open battery cover @ on the left side of the machine body.

Locked connector CN4 @ can be used as a power source.
Remove the male side of the connector and connect a device to be
used. The capacity of the connector is 480 W (24 V x 20 A).
l Machines equipped with cab

It is possible to remove the cigarette lighter and use the socket
as a power supply.
Capacity of cigarette lighter: 120 W (24 V x IO A).
2-13
11.7 LIFT ARM STAY
l When inspecting or maintaining with the lift arm raised, be
l When driving the machine forward or backward, be sure to
The lift arm stay is a safety device of the bucket. Use it when
working the lift arm raised.
Store the lift arm stay to underside the left-hand fender.

If the lift arm stay cannot be pulled out because of the weight of
the lift arm, set the bucket control lever in RAISE position to raise
the lift arm, then pull out the stay.
11.8 MANUAL POCKET

The operator’s seat has a manual pocket in the back of backrest.
This manual should be kept in it for reference and periodical
reviewing.
.2-l 4
12. OPERATION
12.1 CHECK BEFORE STARTING ENGINE

12.1.1 WALK-AROUND CHECK
a WARNING
l If someone touches the control lever by mistake, the machine
may start moving. When leaving the operator’s seat, set the
safety lock to the lock position.
l Combustible materials, fuel or oil around the hot parts of the
engine such as the engine muffler, turbocharger, etc. or the
battery can catch fire. Check around those parts carefully. If
any trouble is found, repair or call our distributors.
Before starting the engine, look around the machine and under
the machine to check for loose nuts or bolts, or leakage of oil, fuel,
or coolant, and check the condition of the work equipment and
hydraulic system.
Check also for loose wiring, play, and collection of dust at places
which reach high temperatures.
2-35
1. Check for damage, wear, play in work equipment, cylinders,
linkage, hoses
Check that there are no cracks, excessive wear, or play in the
work equipment, cylinders, linkage, or hoses. If any abnormality
is found, repair it.
2. Remove dirt and dust from around engine, battery radiator

Check if there is any dirt or dust accumulated around the engine
or radiator. Check also if there is any flammable material (dead
leaves, twigs, grass, etc.) accumulated around the battery or
high temperature engine parts, such as the engine muffler or
turbocharger, Remove all such dirt or flammable material.
3. Check for leakage of water or oil around engine

Check that there is no leakage of oil from the engine or leakage
of water from the cooling system. If any abnormality is found,
repair it.
4. Check for loose air cleaner mounting bolt and muffler mounting
bolts
If the air cleaner or muffler is damaged, repair it, and retighten
the mounting bolts.
5. Check for oil leakage of oil from power train case, final drive
case, hydraulic tank, hose, joints
Check that there is no oil leakage. If any abnormality is found,
repair the place where the oil is leaking.
Check for leakage of oil from the undercover. Check the ground
for traces of oil leakage.
6. Check the undercarriage (track, sprocket, idler, guard) for dam-

age, wear, loose bolts, or leakage of oil from rollers
If any damage, wear, or oil leakage is found, repair the problem
and tighten the bolts.
7. Check for damage to handrail, loose bolts

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

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

Check that there is no abnormality in the seat belt or mounting
clamps. If there is any damage, replace with new parts.
2-16
12. OPERATION
10. Inspection of electric wiring
a WARNING
If the fuses are broken frequently or there is a trace of short
circuit on the electric wiring, be sure to find out the cause and
repair it.
Check the fuses for damage and the electric wiring for a trace of
short circuit. Check the terminals for looseness and retighten loos-
ened ones.
Check the following items, in particular.
l Battery
0 Starting motor
l Alternator
Ask one of our distributors for finding out the cause of the
trouble and repairing it.
4L WARNING
o If dead leaves, twigs, grasses, etc. accumulate around the
battery, they may catch fire. Be sure to remove them.
l Keep the top of the battery clean. Check the vents of the
battery caps for clogging, and wash clogged battery caps in
water.
Remove any combustible materials from around the battery

during the walk-around check and check before starting.
2-17
12.1.2 CHECK BEFORE STARTING
CHECK AND REFILL COOLANT
7 a WARNING
Do not remove cap @ while cooling water is hot. Hot water may
spout out.
When removing cap 0, wait until the water temperature goes
down and release radiator pressure little by little by loosening
caps slowly, then remove the cap.
1. Open the top cover at the front part of the machine body.
2. Remove radiator cap @ and confirm that the coolant is filled up

to the neck of water filler. Refill new coolant, if necessary.
NOTICE
If more coolant than usual is required, it may be leaking from
somewhere. Check for leakage in this case.
CHECK FUEL LEVEL
g WARNING
When adding fuel, never let the fuel overflow. This may cause
a fire. If spilling fuel, thoroughly clean up any spillage.
1. Check the fuel level using fuel gauge 0.
2. After completing work, fill the fuel tank through oil filler port 0.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
3. After adding fuel, tighten the cap securely.

Fuel capacity: 400 !J
NOTlCE
A clogged cap breather hole 0 may stop the fuel flow to the
engine. Check it from time to time and clean.
AD054210
2-18
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
1. Open the upper cover at the front of the machine.
2. Remove dipstick @ and wipe the oil off with a cloth.
3. Insert dipstick @ fully in the oil filler pipe, then take it out again.
4. The oil level should be between the H and L marks on dipstick

0.
If the oil level is below the L mark, take out the dispstick and add
engine oil through oil filler 0.
5. If the oil is above the H mark, drain the excess engine oil from
drain plug, and check the oil level again.
ADO52340
6. If the oil level is correct, tighten the oil filler cap securely, insert
oil level gauge @ fully into the dipstick guide, then close the
upper cover.
REMARK
l When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.
l If the machine is at an angle, make it horizontal before checking.
l When adding oil, remove the oil level gauge from the gauge
guide so that the air in the crank case will be released.
2-19
12. OPERATION
CHECK OIL LEVEL IN TRANSMISSION CASE (INCLUDING TORQUE

CONVERTER CASE), ADD OIL
1. Open the cover, remove dipstick 0, and wipe the oil off with a
cloth.
2. Insert dipstick @Jfully in the oil filler pipe, then take it out again.

0.
If the oil level is below the L mark, add engine oil through oil filler
0.
drain plug @, and check the oil level again.
AD052340
5. If the oil level is correct, tighten the oil filler cap securely and
close the cover.
REMARK
l When stopping the engine, check the oil level.
checking.
If the machine is at an angle, make it horizontal before checking.
2-20
CHECK OIL LEVEL IN STEERING CLUTCH CASE, ADD OIL
1. Remove dipstick 0, and wipe the oil off with a cloth.
2. Insert dipstick @ fully in the oil filler pipe, then take it out again.
_
0.
0.
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. 1
4. If the oil level is above the H mark, drai the excess engine oil
from drain plug 8, and check the oil level again.
5. If the oil level is correct, tighten the oil filler cap securely.
REMARK
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before check-
ing.
2-21
12. OPERATION
CHECK DUST INDICATOR

1. Check that the red piston has not appeared in the transparent
portion of dust indicator 0.
2. If the red piston has appeared, clean or replace the element

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

indicator 0 to return the red piston to its original position.
I ADO52091
CHECK STEERING PEDAL TRAVEL

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

diagram on the right) should be 127 - 191 mm (5.0 - 7.6 in).
3. When this value exceeds 192 mm (7.7 in), or the brake fails to & 127-191 mm
work, please contact your Komatsu distributor for adjustment. (5. O-7. 6 in) AD,,226B
2-22
12. OPERATION
CHECK THAT LAMPS LIGHT UP
1. Insert the key into starting switch @ and turn the key to the ON
HEA?
position. OFF
START
2. Confirm that the lamps light up by operating lamp switch 0.

OFF position: Lamps are turned off.
Position 1: Headlight and instrument lights are turned on.
Position 2: Headlight, instrument light, and rear working lamps
are turned on.
If any of the lamps does not light up, ask our distributor to
inspect the machine.
AD142039
CHECK HORN SOUND
position.
2. Push the horn switch @ and check that the horn sounds.
AM142040
2-23
CHECK BACKUP ALARM SOUND (OPTION)
1. Insert the key into starting switch @) and turn the key to the ON
position.
AE214499
2. Set gear shift lever @ to the rear position.

The buzzer must sound immediately. It keeps sounding until the
gear shift lever is set to “NEUTRAL” or “FORWARD” position.
Rl
I AD205110
CHECK SEAT BELT FOR WEAR OR DAMAGE (OPTION)

Check the belt and mounting clamps, and if they are worn or
damaged, replace the seat belt.
2-24
12. .OPERATION
12.1.3 ADJUST OPERATOR’S SEAT
l Adjust the seat position at the beginning of each shift or
l Adjust the seat so that the brake pedal can be depressed all
the way with the operator’s back against the backrest.
Fore-aft adjustment of seat

Move lever 0 to the left set the seat to a position where it is easy
to operate, then release the lever.
Fore-aft adjustment: 160 mm (6.3 in) (9 stages)
Adjustment of cushion
Turn knob @ to eliminate gap (A) between the end of chain @
and the frame. At this point, the seat is set under the best condition.
Tilting the seat forward

Pull lever @ and pull the seat back, and the seat is tilted forward.
AN142280
2-25
12.1.4 USING SEAT BELT (OPTION)
When operating a machine equipped with ROPS, be sure to use
the seat belt.
I A WARNING
Before fastening the seat belt, inspect the securing brackets
and belt for abnormal conditions.
Replace any worn or damaged seat belt or the securing
brakets.
Adjust and fasten the seat belt before operating the machine.
Always use the seat belt when operating the machine.
Do not use seat belt with either half of the belt kinked.
FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER 1 A

1. Adjust the seat so that the brake pedal can be depressed all the
way with the operator’s back against the backrest.
2. After positioning the seat, adjust the tether belt 0. With the seat
unoccupied, tense the belt slightly across the seat and install.
3. Sit in the seat. Hold buckle @ with your left hand and tonque @
with your right hand, put the tonque 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 kinking 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.
ADJUST THE BELT LENGTH IN THE FOLLOWING MANNER
TO SHORTEN THE BELT

Pull the free end of the belt on either the buckle body or tonque
side.
AM088710
TO LENGTHEN THE BELT

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 24.5 f 4.9 Nm (2.5 f 0.5 kgfm, 18 +. 3.6 Ibft) torque.
If the seat is scratched or frayed or if any of the fittings are

broken or deformed from long service, replace the seat belt imme-
AM088720
diately.
2-26
12.1.5 OPERATIONS AND CHECKS BEFORE STARTING
ENGINE
If the control levers are touched by accident, the work equip-

ment or the machine may move suddenly. When leaving the
operator’s compartment, always set the safety lock lever se-
i’ curely to the LOCK position. WARN’NG
1. Confirm that the steering pedals are locked with brake lock lever
0.
2. Confirm that the gear shift lever is at N (NEUTRAL) position and

locked with safety lock lever 0.
ee a
ADl4231B
3. Check that the bucket is lowered on the ground and the bucket
control lever is locked with safety lock lever 0. Lock 0
Free a
AD142328
2-27
12.2 STARTING ENGINE
12.2.1 NORMAL STARTING
Ah WARNING
Check that there are no persons or obstacles in the surrounding
area, then sound the horn and start the engine.
NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine will not start, wait for at least 2 minutes before
trying to start the engine again.
1. Pull fuel control lever @ to a position a little past the LOW IDLING
position toward the HIGH IDLING position. Low idline
naine stop
2. Turn the key of starting switch @ to the START position. The

engine will start.
3. When the engine starts, release the key in starting switch 0. The
key will return automatically to the ON position.
START
AE21451B
2-28
12.2.2 STARTING IN COLD WEATHER
When starting in low temperatures, do as follows.
A WARNING
Never use starting aid fluids as they may cause explosions.
NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine fails to start, repeat steps 2 and 3 after waiting for
about 2 minutes.
1. Pull fuel control lever @ to a position a little past the LOW IDLING I
position toward the HIGH IDLING position. idling
2. Turn the key of starting switch @to the HEAT position and hold
HEAT
it until glow signal @ glows red.
NF
The preheating times are as shown below.
AE21452.3
If the preheating time is too long or too short, the engine will not
start easily. Observe the correct preheating time.
3. When glow signal @ becomes red, turn the key of starting switch
@ to the START position and start the engine.
START
AE21453B
2-29
1. When the engine starts, release the key in starting switch 0. The
key will return automatically to the ON position. HEA:
START
AE21451B
2-30
12.3 OPERATIONS AND CHECKS AFTER
STARTING ENGINE
After starting the engine, do not immediately start operations.
First, carry out the following operations and checks.
NOTICE
Avoid abrupt acceleration until warm-up run is completed.
Do not run the engine at low idling or high idling for more than
20 minutes. If it is necessary to run the engine at idling, apply a load
or run at a medium speed from time to time.
1. Pull fuel control lever @ to the center position between LOW

Mid idling
IDLING and HIGH IDLING and run the engine at medium speed Low idling
for about 5 minutes with no load.
2. After warm-up run is completed, check gauges, warning lamps

and charge lamp for proper operation. If any abnormality is
found, repair it.
Continue to run the engine at light load until engine water
temperature gauge indicator @ falls within the white range.
3. Check that there is no abnormal exhaust gas color, noise, or

vibration. If any abnormality is found, repair it.
CHECK BACKUP ALARM SOUND (OPTION)
1. Press decelerator pedal @ to lower the engine speed.
AM142500
2-31
12. OPERATION
2. Press the center between both steering pedals @ to apply the

brake. Lock the brake with brake lock lever 0. Lock 0
t
aa
AD14260B
3. Set safety lock lever @ of the gear shift lever to FREE position.
4. Set gear shift lever @ to position RI and confirm that the backup
alarm sounds. N
Rl
AD205110
2-32
12.4 MOVING MACHINE OFF
A WARNING
When starting the machine, check for the safety around, and
sound the horn.
Do not let any one approach the machine.
When moving the machine in reverse, be careful of the rear
of the machine which cannot be seen from the operator’s
seat.
When starting the machine on a slope, be sure to keep
pressing the center between steering pedals @ even after
setting brake lock lever @ free.
When starting the machine on a steep uphill slope, raise the
engine speed to the full level and set gear shift lever @) to 1st
Gear with the center of steering pedals @ pressed. After the
machine starts (or the shoe slips) slowly, release the steering
pedals slowly to start the machine.
If the machine is equipped with the backup alarm (option), set
gear shift lever 0 in the reverse position and confirm that the
alarm operates normally.
1. Pull fuel control lever @ to increase engine speed.
AD142428
2. Set safety lock lever @ for bucket control lever @ to the FREE @
position. Lock 0
Free a
AD14243B
3. Pull bucket control lever @ in the RAISE position to raise the

blade 40 - 50 cm (16 - 20 in) off the ground.
2-33
4. Press the center between both steering pedals @ and push brake
lock lever @ to set it free, then return the pedal. Lack 0
Keep pressing steering pedals 0. 4
aa
AD142456
5. Set safety lock lever @ of the gear shift lever free.
Free a
I AD142466
6. Set gear shift lever @ to the desired position.
Rl Fl
R2 F2
R3 F3
AM142470
7. Release the center between both steering pedals 0, and start the
machine.
12.5 SHIFTING GEAR

There is no need to stop machine to shift gears.
Set gear shift lever 0 in the desired position to shift gear.
RI Fl
R2 F2
R3 F3
AM142470
2-34
12.6 ;;lFz;NV BETWEEN FORWARD AND
&h WARNING
Forward-reverse shifting should be made after reduction of
machine speed for safety purpose and preventing shock to
machine.
AM142490
1. Press decelerator pedal @ to lower the engine speed.
I AM142500 1
2. Change gear shift lever @ to the desired position.
Rl Fl
R2 F2
R3 F3
J
AM142470
3. Return decelerator pedal @I and raise the engine speed.
I 1
AMl49610
4. If the machine is equipped with backup alarm, confirm that the

alarm sounds when gear shift lever @ is placed in the reverse
position.
If the alarm does not sound, ask your Komatsu distributor for
repairs.
2-35
12.7 STEERING MACHINE
l Avoid as much as possible turning the machine on a slope.
l Never make a pivot turn at high speed.
12.7.1 NORMAL TURNING
If either steering pedal @ is pressed during travel, the machine

turns toward the direction of the pressed pedal.
I
AM142520 1
l When turning to the left slowly

Press the left-hand steering pedal halfway, and the steering
clutch is disengaged and the machine turns to the left slowly.
REMARK
When turning to the right slowly, operate the right-hand steering
pedal similarly to the above.
AN142530
l When performing a pivot turn to the left

Press the left-hand steering pedal to the end, the steering clutch
is disengaged and the steering brake is applied, and the machine
performs a pivot turn to the left.
REMARK
When performing a pivot turn to the right, operate the right-hand
steering pedal the same as described above.
AN142540
2-36
12. OPERATION
12.7.2 TURNING WHILE DESCENDING A SLOPE
A WARNING p
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 the direction of the moved lever.
l When turning to the left slowly

Press the right-hand steering pedal halfway, and the machine
turns to the left slowly (Counter steering).
REMARK
When turning to the right slowly, operate the left-hand steering
pedal similarly to the above (Counter steering).
AN142550
l When performing a pivot turn to the left

Press the left-hand steering pedal to the end, and the machine
performs a pivot turn to the left (Normal steering).
REMARK
When performing a pivot turn to the right, operate the right-hand
steering pedal similarly to the above (Normal steering).
AN142560
2-37
12.8 STOPPING MACHINE
A WARNING
l Avoid stopping suddenly. Give yourself ample room when
stopping.
l When stopping the machine, select flat hard ground and
avoid dangerous places. If it is unavoidably necessary to park
the machine on a slope, insert blocks underneath the track
shoes. As an additional safety measure, thrust the bucket into
the ground.
l If the control lever is touched by accident, the work equip-
ment or the machine may move suddenly, and this may lead
to a serious accident. Before leaving the operator’s compart-
ment, always apply the lock securely.
1. Lower the engine speed with the fuel control lever 0.
iIff
I
I ADl4258B
2. Set the gear shift lever @ to N (Neutral) position.

N
F
1 1
2 2
3 3
An142590
3. Press the center between both steering pedals @I_Lock the brake
with brake lock lever 0.
ADl4260B
4. Lock gear shift lever @ with safety lock lever 0.
Free a
ADl4231B
2-38
12. OPERATION
5. Lower bucket control lever @to lower the bucket to the ground.
w
0 Lower
t
7-n-%90
6. Lock bucket control lever @ with the safety lock lever 0.

Lock
Free
AD142328
2-39
12. OPERATION
12.9 PRECAUTIONS FOR OPERATION

12.9.1 METHOD OF USING STEERING CLUTCH
If the steering clutch one side is used frequently or if many
gradual turns are made with steering clutch half-engaged, the steering
clutch will wear out in a short time. Design the travel road well and
steer the machine properly.
12.9.2 PERMISSIBLE WATER DEPTH

When operating in water, always keep the bottom of the carrier
roller above the surface of the water.
Also, be careful that the engine cooling fan will not come in
contact with water. The fan can be damaged.
12.9.3 PRECAUTIONS WHEN TRAVELING UP

OR DOWN HILLS
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.
Never coast down slope with the gear shift lever in the N
(neutral) position or with the inching pedal depressed.
Braking when traveling downhill

While descending a slope using the engine as a brake, also apply
the brakes.
Failure to brake may result in overrunning, causing engine
trouble.
12.9.4 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
machine or the swaying of the machine. If this makes the engine
stop, so be careful not to let the fuel level in the fuel tank become
too low.
Precautions when engine stops on slopes

If the engine stops while working or traveling on a hill, immedi-
ately depress the brake pedal, lower the bucket to the ground to stop
the machine, then lock the brake pedal with the brake lock lever.
Thereafter, move the gear shift lever to the N (neutral) position,
lock the lever, then restart the engine.
2-40
12. OPERATION
12.10 WORK POSSIBLE USING DOZER SHOVEL

In addition to the following, it is possible to further increase the
range of applications by using various attachments.
12.10.1 EXCAVATION
0 Scoop up the piled soil by moving the machine forward as
shown. If the track shoe begins slipping under heavy load, raise
the bucket slightly to reduce the load.
1. Force the bucket into the pile of soil while moving the machine
forward.
2. After the bucket has fully penetrated into the soil, place the
bucket control lever in RAISE position while moving the machine
forward. Move the bucket control lever to TILT position from
time to time until the bucket is filled with soil.
AN142660
L
3, When it is difficult for the bucket to penetrate into the piled soil,
move the bucket control lever left and right to move the bucket
teeth up and down.
I AN142670
0 In an excavating-loading operation on flat ground, move the y

machine forward with the bucket teeth facing somewhat down-
ward as shown. In this case, do not impose the load on one side
only.
1. Direct the bucket teeth somewhat downward from the horizon-
tal.
AN142660
2. Scrape the soil gradually by pushing the bucket control lever a

little forward while moving the machine forward.
AN142690
2-41
3. Move the machine forward while adjusting the digging depth by
means of the bucket control lever.
REMARK
When digging with the bucket, avoid imposing the digging force
onto only one side of the bucket.
12.10.2 LOADING
When loading the earth on truck, shorten cycle time and increase
work efficiency by minimizing turns and travel distance.
Dozer shovel can transport newly mixed concrete direct to
molds.
12.10.3 LEVELING
1. Scoop up the soil into the bucket, drive the machine in reverse,
and dump the bucket a little at a time to dump the soil.
2. With the bucket at the dump position, lower the bucket until the
bucket edge is in contact with the ground, then drive in reverse
with the bucket dragging along the ground to level the soil.
3. Fill the bucket with soil, set the bucket in a horizontal position,
place the boom at FLOAT, then drive in reverse to finish the
surface.
NOTICE
If dumping is performed with dumping cylinder fully extended
(up to stroke end), dumping cylinder may be damaged when sub-
jected to excess load. Therefore, always dump with dumping cylin-
der slightly retracted from fully extended position.
12.10.4 BACK FILLING

For back filling in foundation work at construction sites, with
bucket kept horizontally, dump the first excavated soil without
dumping it over, and use each succeeding excavated soil to push the
previous excavated soil over. Be sure not to approach the edge by
mistake.
-.r
/ - AE205140
AE205150
2-42
12.11 HOW TO USE INCHING PEDAL
High-efficiency excavation by effective use of the inching pedal.
12.11.1 OPERATION OF INCHING PEDAL

The inching pedal can be used in the following three ways:
POSITIVE STOP OF A MACHINE DURING OPERATION

When a machine is to be positively stopped between excavating
operations, first depress the inching pedal. Then, the transmission
clutch will disengage, interrupting the flow of power from the
engine. If the brake pedal is depressed, the machine can be stopped
completely.
AH142750
WHEN A MACHINE IS TO APPROACH A TARGET INCH BY INCH

Depress the inching pedal and place the transmission clutch in
the half-disengaged or completely disengaged position. Then the
machine can approach material little by little.
AM142760
SCOOPING IN A DIGGING OPERATION

Scooping can be done as in a direct-drive machine, using the
inching pedal. After depressing the pedal all the way down, release
it little by little. As soon as the transmission clutch is half-engaged,
release the pedal at once. Then, the transmission clutch engages
instantly, enabling the bucket to scoop up material.
AM142710
2-43
12. OPERATION
12.11.2 HOW TO USE INCHING PEDAL

IN ACTUAL MATERIAL HANDLING
OPERATIONS
LOADING
l Approaching a dump truck and correcting the direction of travel
Approach the side of the dump truck and stop the machine by
depressing the inching pedal and brake pedal.
AN142780
Depress the inching pedal all the way down, then depress the
brake pedal.
%OOO
AM142750
When adjusting the turning direction finely, press the steering

pedal in the turning direction, then slowly release the inching pedal
that has been pressed during stoppage.
I AM142800
l Inching approach and bucket speed I I

Depress the inching pedal and bring the transmission clutch to
a half-disengaged or completely disengaged position to inch toward
the dump truck.
I AN142810
REMARK
When inching with the inching pedal, the bucket can operate
even at full engine speed without slowing down the bucket speed.
I AH142760 1
2-44
12. OPERATION
0 Positive stopping
Slowly approach the desired stopping position with the inching
pedal kept halfway down. Stop the machine positively by depressing
the brake pedal all the way down.
REMARK
If the machine is traveling with a full bucket, and the brake pedal *.
is depressed all the way down, it will act like the emergency brake, c
AE205160
possibly causing the machine to lose balance. Consequently, slowly
depress the inching pedal’after bringing the transmission clutch to
the half disengaged position. When the machine has reached the
desired location, depress the brake pedal all the way down to apply
the brake.
b,oO
AM142750
FILLING OPERATION
0 Positive stopping
Slowly bring the machine to the desired stopping position,
depressing the inching pedal halfway. To stop the machine posi-
tively, depress the brake pedal all the way down.
_ ._- AE205170
cs,oo AM142750
CORNERING
l Inching steering and approaching
Operate the steering and directional lever and depress the
inching pedal to bring the transmission clutch to the half disengaged
position for microsteering or inching up to a building.
2-45
EXCAVATION
l Jerking
After depressing the inching pedal all the way down, release the
pedal halfway to bring the transmission clutch to the half disen-
gaged position. Then, release the pedal fully at once, and the
transmission clutch will engage instantly, enabling the bucket to jerk
material.
REMARK
After depressing the inching pedal all the way down, release the
pedal fully at once. Then, the machine can start off smoothly as if
the gear shift lever were put into the desired speed position. In this
case, jerking with the bucket is impracticable.
AM142770
12.11.3 PRECAUTIONS WHEN APPLYING

THE INCHING PEDAL
l Do not keep the inching pedal depressed halfway for more than
10 sec. with the transmission clutch in the half-disengaged
position. This will protect the clutch against excessive wear.
l Do not rest your foot on the pedal unless absolutely necessary.
2-46
12.12 PARKING MACHINE
A WARNING
Avoid stopping suddenly. Give yourself ample room when
stopping.
When stopping the machine, select flat hard ground and
avoid dangerous places. If it is unavoidably necessary to park
the machine on a slope, insert blocks underneath the track
shoes. As an additional safety measure, thrust the bucket into
the ground.
If the control lever is touched by accident, the work equip-
ment or the machine may move suddenly, and this may lead
to a serious accident. Before leaving the operator’s compart-
ment, always apply the lock securely.
1. Lower engine speed by operating fuel control lever @I_

Low idling
2. Place gear shift lever @ in NEUTRAL position.
m
N
a
1
F
1
2 2
3 3
I I J
AM142590
Press the center between both steering pedals 0. Lock the brake
with brake lock lever 0. Lock 0
t
a&
AD142600
4. Lock gear shift lever @ with safety lock lever 0.
ee d
2-47
12. OPERATION
5. Put bucket control lever @ in the LOWER position to lower the

bucket to the ground while keeping it horizontal.
AD142628
6. Lock bucket control lever @ with safety lock lever 0.

Lock
Free
AD142328
12.13 CHECK AFTER FINISHING WORK

1. Check the gauges and lamps for engine water temperature,
engine oil pressure, fuel level and air cleaner clogged.
2-46
12.14 STOPPING ENGINE
NOTICE
If the engine is abruptly stopped before it has cooled down,
engine life may be greatly shortened. Consequently, do not abruptly
stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly stop
it but run it at medium speed to allow it to cool gradually, then stop I
AM162470
it.
1. Run the engine at low idling speed for about 5 minutes to allow
it to gradually cool down.
2. Pull the knob and set fuel control lever @ to ENGINE STOP
position to stop the engine. Low idline
naine stop
nob
3. Turn the key in starting switch @ to the OFF position and stop
the engine.
4. Remove the key from starting switch 0.
2-49
12.15 CHECK AFTER STOPPING ENGINE
1. Walk around the machine and check the work equipment, paint-
work, and undercarriage, and check also for leakage of oil or
water. If any abnormalities are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out
any paper and debris to avoid a fire hazard.
4. Remove any mud stuck to the undercarriage.
2-50
12.16 TIPS FOR LONGER UNDERCARRIAGE
LIFE
Undercarriage life greatly varies depending on operation method,
inspection and maintenance. For most efficient operation, keep the
following point in mind.
12.16.1 OPERATION METHOD

Select the track shoe that best suits the type of soil to be
encountered in service.
Please consult your Komatsu distributor when selecting track
shoes.
Do not allow shoe slipping to occur during operation. If shoe

slipping occurs, reduce load to the bucket until slipping stops.
Avoid sudden starts, acceleration or stops, unnecessarily high

speeds and sharp turns.
Always operate machine in a straight line whenever possible.

When making turns, be careful not to allow the machine to stay
to one side, so operation in both turning directions can be done
properly. Make turns with the largest possible radius.
Prior to operation, clear boulders and obstacles to prevent

machine from riding over them while operating.
On a slope, operate the machine parallel to the inclination of the

slope. Do not operate across the slope. Also when stopping the
machine on a slope, the machine should face toward the top of
the slope.
When ground inclines to left or right during digging operation,

do not continue to dig with machine inclined. Move machine
back to level ground and start to dig again.
When idlers or sprockets are lifted due to obstacles during

dozing, do not attempt to force the machine to perform. Because
work at this time exceeds machine working capability.
2-51
12. OPERATION
12.16.2 INSPECTION AND ADJUSTMENT Clearance A

l Properly adjust track tension.
Tension should be measured at clearance @ shown in the
diagram - usually 20 to 30 mm (0.8 to 1.2 in) at this point. For
rocky terrain, tighten tracks slightly. In clay or sandy areas,
slightly loosen them. (For inspection and adjustment proce- -
dures, refer to “24.2 WHEN REQUIRED”).
AE14294B
l Check idler rollers for oil leakage as well as for loose bolts and
nuts. If any trouble is detected, repair immediately.
l Check the clearance between the idler guide plate and the track
frame. If clearance @ increases, idler may develop side motion
and tracks may come off. (For inspection and adjustment proce-
dures, refer to “24.2 WHEN REQUIRED”.)
12.16.3 INSPECTION AND REPAIR

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

1. Insert a wooden block between track shoe and sprocket to take
up the slack in track shoes.
2. Measure pitch length of 4 links in stretched portion at more than

2 links away from master pin. Of length obtained, l/4 is the link
pitch.
AN142960
Standard link pitch (PI:
216.25 mm (8.65 in)
Reversing limit link pitch: (1/4L)
219.25 mm (8.77 in) (At heavy-duty work)
221.25 mm (8.85 in) (At light-duty work)
t-7
REMARK
A center hole is not provided on both ends of master pin. ON
AD142978
2-52
i2. OPERATION
MEASURING HEIGHT OF GROUSER

After taking up slack in track shoes, measure height at center of
shoe as shown.
Standard height (h): 36.0 mm (1.44 in)
Repair limits: 20.0 mm (0.8 in)
AD205190
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-0x2
Standard size (A): 222 mm (8.88 in)
Repair limits: 197 mm (7.88 in)
AD205200
2-53
13. TRANSPORTATION
When transporting the machine, observe all related laws and

regulations, and be careful to assure safety.
13.1 LOADING, UNLOADING WORK

4b WARNING
l Make sure the ramp has sufficient width, length and thick-
ness to enable the machine to be safely loaded and unloaded.
If the ramp sags appreciably, reinforce it with blocks, etc.
l When loading and unloading the machine, park the trailer on
a flat firm roadbed. Keep a fairly long distance between the
road shoulder and the machine.
l Remove the mud from the undercarriage to prevent the
machine from slipping to the side on slopes.
Be sure the ramp surface is clean and free of grease, oil, ice
and loose materials.
l Never change the direction of travel when on the ramps. If it
is necessary to change direction, drive off the ramps and
correct the direction, then drive on to the ramps again.
When loading or unloading, always use ramps or a platform and

carry out the operations as follows.
1. Properly apply the brakes on the trailer and insert blocks beneath
the tires to ensure that it does not move. Then fix the ramps in
line with the centers of the trailer and the machine. Be sure that
the two sides are at the same level as one another. Ra
2. Determine the direction of the ramps, then slowly load or unload

the machine.
Distance between ramps
3. Load the machine correctly in the specified position on the
trailer.
2-54
13. TRANSPORTATION
13.2 PRECAUTIONS FOR LOADING, AND

SECURING THE MACHINE
After loading to the specified position, secure the machine as

follows.
1. Lower the work equipment slowly.
2. Lock all the control levers securely with the safety lock lever.
3. Set the parking lever to the LOCK position.
4. Set the fuel control lever to the ENGINE STOP position to stop
the engine, then turn the starting switch to the OFF position and
remove the key.
5. For avoiding slip of the machine, secure it tightly as follows.

l Put blocks @ in front and behind the track shoes of both
sides.
l Set up chain or wire, following @ or @I.
@: Set up chain or wire around the track shoes.
@I: Set up chain or wire through the holes of track links.
l Protect the wire from contacting directly with angular parts
of the machine, by inserting pads.
6. Confirm that the height of the load clears various limitations on

the way (width and height of tunnels, size of guards, branches
of trees) and meets all laws and regulations governing transpor-
tation.
Refer to “13.4 PRECAUTIONS FOR TRANSPORTATION”.
2-55
13. TRANSPORTATION
13.3 LIFTING THE MACHINE

I a
1
DANGER
While lifting the machine, if wire or rope is not fitted correctly
the machine may fall and cause serious injury or even death.
Raise the machine 100 - 200 mm (4 - 8 in) from the ground,
check that the machine is horizontal and that there is no slack
in the wire rope, then continue to lift the machine.
Before lifting the machine, always stop the engine and lock
the parking brake.
IA WARNING
Lifting operations using a crane must be carried out by a
qualified operator.
Never raise the machine with any worker on it.
Always make sure that the wire rope used for lifting the
machine is of ample strength for the weight of the machine.
Never try to lift the machine at any position or in any
procedure other than the posture given in the procedure
below. There is danger that the machine may lose its balance.
NOTICE
l For details of the weight, see “25. SPECIFICATIONS”.
l The values given for the specifications are for the standard
machine, so the method of lifting may differ according to the
options and attachments actually installed. In such cases please
contact your Komatsu distributor for advice.
2-56
13. TRANSPORTATION
13.3.1POSITION FOR AlTACHlNG LIFUNG POSITION MARKS
0 Lifting image mark

(I 45-98-5 1880)
145-98-51880-
AE21509B
FOR DETAILS OF THE WEIGHT, SEE “25. SPECIFICATIONS”.
2-57
13.3.2 LIFTING PROCEDURE
l Detail of installation of ropes
A
to inside of track and frame
of work equipment
Install to
Ti It bucket back al
an d apply safety
IO ck
Pass at behind the idler

l Detail of installation of
! I=\ ropes to diagonal brace
Pass inside track, then
under undercover AD215106
Diagonal Wind rope

brace onto brace
ADD I Y
protector
AE2146lB
Tilt bucket diagonal brat
l Detail of installation of ropes

to ripper beam
Pass under behind the idler I nsta’l I to

ripper beam
Pass inside track. then AE214630
under undercover AD215116
2-58
13. TRANSPORTATION
Before starting the lifting operation, stop the machine in a

horizontal place and do as follows.
1. Stop the engine, depress the brake pedal fully, then pull the
brake lock lever to lock the brakes.
2. As shown in the diagram in previous page, use wire rope, slings

or other lifting equipment according to the weight, pass the wire
rope around the lifting position, then fit it to a crane.
NOTICE
Fit protectors at sharp corners or places where the wire rope
may cut into the contact point in order to protect the machine
and prevent the wire rope from being cut.
Choose a sledder and bar of ample width which will not contact
the chassis.
When the machine leaves the ground, stop for a moment at a

point 100 - 200 mm (4 - 8 in) from the ground, check that there
is no slack in the wire rope and that the machine is horizontal,
then continue the lifting operation slowly.
13.4 PRECAUTIONS FOR TRANSPORTATION

a WARNING
Determine the route for transporting the machine by taking into
account the width, height and weight of the machine.
Obey all state and local laws governing the weight, width and
length of a load. Observe all regulations governing wide loads.
2-59
14. COLD WEATHER OPERATION
14.1 PRECAUTIONS FOR LOW TEMPERATURE
If the temperature becomes low, it becomes difficult to start the

engine, and the coolant may freeze, so do as follows.
14.1.1 FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components.
For details of the specified viscosity, see “20. USE OF FUEL,
COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE”.
14.1.2 COOLANT
Keep antifreeze fluid away from an open flame. Never smoke
NOTICE
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 spring
and autumn). When refilling the cooling system, add antifreeze in
autumn, but do not add any in spring.
Absolutely avoid using any water leak preventing agent irrespec-
tive of whether it is used independently or mixed with an antifreeze.
Do not mix one antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant,
see “24.1 WHEN REQUIRED”.
Use a Permanent Antifreeze (ethylene glycol mixed with corro-
sion inhibitor, antifoam agent, etc.) meeting the standard require-
ments as shown below. With permanent antifreeze, no change of
coolant is required for a year. If it is doubtful that an available
antifreeze meets the standard requirements, ask the supplier of that
antifreeze for information.
Standard requirements for permanent antifreeze.
l SAE ..... .... ........ ..... ............. ............. ............. .............. ............. . J1034
l FEDERAL STANDARD ...... .............. .............. ............ .... O-A-548D
2-60
14.1.3 BATTERY
A WARNING
l To avoid gas explosions, do not bring fire or sparks near the
battery.
l Battery electrolyte is dangerous. If it gets in your eyes or on
your skin, wash it off with large amounts of water, and
consult a doctor.
When the ambient tem’perature drops, the capacity of the battery

will also drop. If the battery charge ratio is low, the battery electro-
lyte may freeze. Maintain the battery charge as close as possible to
lOO%, and insulate it against cold temperature so that the machine
can be started easily the next morning.
Measure the specific gravity and calculate the rate of charge

from the following conversion table.
20°C 0°C -10°C -20°C
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
14.2 AFTER COMPLETION OF WORK
To prevent mud, water, or the undercarriage from freezing and

making it impossible for the machine to move on the following
morning, alwavs 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 impos-
sible, park the machine on wooden boards. The boards help
protect the tracks from being freezed in soil and the machine can
start next morning.
Open the drain valve and drain any water collected in the fuel
system to prevent it from freezing.
As the battery capacity drops markedly in low temperatures,
cover the battery or remove it from the machine, keep it in a
warm place, and install it again the next morning.
If electrolyte level is found low, add distilled water in the morn-
ing before beginning work. do not add the water after the day’s
work so as to prevent fluid in the battery from freezing in the
night.
2-61
14.3 AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as
follows.
l Replace the fuel and oil for all parts with oil of the viscosity
specified.
For details, see “20. USE OF FUEL, COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE”.
l 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.
2-62
15. LONG-TERM STORAGE
15.1 BEFORE STORAGE

When putting the machine in storage for more than one month,
do as follows.
0 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, park the machine
on the flat ground and cover it with canvas etc.
Completely fill the fuel tank, lubricate and change the oil before
storage.
Apply a thin coat of grease to metal surface of the hydraulic

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

remove it from the machine and store it separately.
If the ambient temperature is expected to drop below O”C,

always add antifreeze to the cooling water.
Lock each control lever with the safety lock and place the fuel
control lever in the low idling position. Do not lock the brake
pedal; use blocks to stop the machine from moving.
15.2 DURING STORAGE
If it is unavoidably necessary to carry out the rustpreventive
windows to improve ventilation and prevent gas poisoning.
l Operate the engine and move the machine for a short distance
once a month so that a new film of oil will be coated over
movable parts and component surfaces. At the same time, also
charge the battery.
l Before operating the work equipment, wipe off the grease on the
hydraulic piston rod.
15.3 AFTER STORAGE
NOTICE
If the machine is stored without carrying out the monthly rust
prevention operation, request your Komatsu distributor for service.
Carry out the following procedure when taking the machine out
of long-term storage.
l Wipe off the grease from the hydraulic cylinder rods.

l Add oil and grease to all places.
2-63
16. TROUBLESHOOTING
16.1 AFTER RUNNING OUT OF FUEL

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
system before starting.
For details of bleeding the air, see “24.6 EVERY 500 HOURS SERV-
ICE”
16.2 IF BATTERY IS DISCHARGED

A WARNING
When checking or handling the battery, stop the engine and
turn the starting key to the OFF position before starting.
The battery generates hydrogen gas, so there is danger of
explosion. Do not bring lighted cigarettes near the battery, or
do anything that will cause sparks.
Battery electrolyte is dilute sulphuric acid, and it will attack
your clothes and skin. If it gets on your clothes or on your
skin, wash it immediately off with large amounts of water. If
it gets in your eyes, wash it out with fresh water, and consult
a doctor.
When handling battery, always wear-protective goggles and
rubber gloves.
When removing the battery, first disconnect the cable from
the ground (normally, from the negative 0 terminal). When
installing, install the positive @terminal first. If a tool touches
the cable connecting the positive terminal and the chassis,
When installing, connect the
there is danger that it will cause sparks. cable to the positive @ ter-
minal first.
If the terminals are loose, there is danger that the defective
contact may generate sparks that will cause an explosion.
When installing the terminals, install them tightly.
16.2.1 STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:
/ w AM087770
2-64
REMOVAL, INSTALLATION OF BATTERY
1. Open battery cover 0.
2. Disconnect the grounding cable (from the 0 (negative) terminal,

usually) first. If a tool, etc. touches the @ (positive) terminal and
the machine body simujtaneously, sparks will be produced.
Loosen the terminal nut and disconnect the cable from the
battery.
When removing, disconnecf the
3. When connecting, connect the grounding cable at last. Inset-t the
terminal hole to the battery, then tighten the nut.
Tightening torque: 5.88 - 9.81 N-m IO.6 - 1.O kgf.m, 1.2 - 2.0 Ibft)
4. Close battery cover 0.
minal first.
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING

BOOSTER CABLE
a WARNING AM087770
When starting the engine from another machine, connect the

batteries in parallel.
When connecting the cables, never contact the positive @
and negative @ terminals.
When starting the engine with a booster cable, always wear
safety glasses.
Be careful not to let the normal machine and problem ma-
chine contact each other. This prevents sparks from generat- AM087790
ing near the battery which could ignite the hydrogen gas
given off by the battery. If hydrogen gas explodes. It could
cause serious injury.
Make sure that there is no mistake in the booster cable
connections. The final connection is to the engine block of the
problem machine, but sparks will be generated when this is
done, so connect to a place as far as possible from the
battery.
Use care when removing the cables from the machine that
has been started. Do not allow the cable ends to contact each
other or the machine, to avoid hydrogen explosion.
NOTICE
l The size of the booster cable and clip should be suitable for the
battery size.
l The battery of the normal machine must be the same capacity

as that of the engine to be started.
l Check the cables and clips for damage or corrosion.
l Make sure that the cables and clips are firmly connected.
2-65
16. TROUBLESHOOTING
CONNECTING THE BOOSTER CABLES

Keep the starting switch at the OFF position.
Connect the booster cable as follows, in the order of the num-

bers marked in the diagram.
1. Make sure that the starting switches of the normal machine and
problem machine are both at the OFF position.
2. Connect one clip of booster cable @ to the positive @ terminal roblem machine
ADO52980
of the problem machine.
3. Connect the other clip of booster cable @ to the positive @
terminal of the normal machine.
4. Connect one clip of booster cable @I to the negative @ terminal
of the normal machine.
5. Connect the other clip of booster cable @ to the engine block of
the problem machine.
STARTING THE ENGINE

1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and keep it to run at high
idling speed.
3. Turn the starting switch to start the engine. If the engine does
not start, wait for at least 2 minutes, then try again.
DISCONNECTING THE BOOSTER CABLES

After the engine has started, disconnect the booster cables in
the reverse of the order in which they were connected.
1. Remove one clip of booster cable @I from the engine block of I I

the problem machine. Battery of the Battery of the
normal machine fi oroblem machine
1 W’
2. Remove the other clip of booster cable @ from the negative 0 ===a
Engine block of the problem machine Aw52e8,
3. Remove one clip of booster cable @ from the positive @

4. Remove the other clip of booster cable @ from the positive @

terminal of the problem machine.
2-66
16. TROUBLESHOOTING
16.3.2 CHASSIS
Problem Main causes Remedy
Transmission oil pressure does not rise 0 Wear or scuff of gear pump 10 Check, replace)
l Insufficient oil in transmission case l Referring to check before starting,
(including torque converter case) supply oil to specified level
0 Clogging of strainer of transmission l Referring to EVERY 1000 HOURS
case SERVICE, clean
Traction force is low 0 Insufficient engine power 0 See section of engine

(Travel speed does not rise)
When gear shift lever is set, l Insufficient oil in steering clutch l Referring to check before starting,
machine does not start case supply oil to specified level
0 Low transmission oil pressure l See above problem of “Transmis-
sion oil pressure does not rise”
l Slip of steering clutch (o Check, replace)
0 Wear or scuff of gear pump
Torque converter overheats 0 Insufficient oil in transmission case l Referring to check before starting,
(Indicator is in red range) (including torque converter case) supply oil to specified level
0 Low transmission oil pressure l See above problem of “Transmis-
sion oil pressure does not rise”
l Slip of steering clutch (o Check, replace)
0 Wear or scuff of gear pump
l Excessive working load l Use gear speed lower by one rank or
reduce load to heighten working
speed.
When either steering pedal is pressed, l Inoperable pressed brake (o Adjust)

machine does not turn but travels
straight
When either steering pedal is pressed, l Improper adjustment of steering (o Adjust)

machine does not turn but stops or mechanism
engine speed changes
When brake pedal is pressed, machine l Wrong adjustment of brake or (o Adjust, check, repair)
does not stop. improper oil pressure
Track comes off l Looseness of track l Referring to WHEN REQUIRED,

adjust track tension
Sprocket is worn abnormally l Looseness of tightness of track
Bucket does not rise (or tilt) quickly or l Insufficiency of hydraulic oil l Referring to EVERY 250 HOURS
at all SERVICE, add hydraulic oil to
specified level.
2-68
16. TROUBLESHOOTING
16.3.3 ENGINE
Problem Main causes Remedy
Engine oil pressure warning l Engine oil pan oil level is low l Add oil to specified level, see CHECK
lamp remains alight when (sucking in air) BEFORE STARTING
engine speed is raised after l Clogged oil filter cartridge l Replace cartridge, see EVERY 250 HOURS
completion of warm-up SERVICE
l Defective tightening of oil pipe (o Check, repair)
and pipe joint, oil leakage from
damaged part
l Defective warning lamp (o Replace lamp)
Steam is emitted from top part Cooling water level low, water Add cooling water, repair, see CHECK
of radiator (pressure valve) leakage BEFORE STARTING
Loose fan belt Adjust fan belt tension, see EVERY 250
HOURS SERVICE
Dirt or scale accumulated in Change cooling water, clean inside of
cooling system cooling system, see WHEN REQUIRED
Clogged radiator fin or damaged Clean or repair, see WHEN REQUIRED
fin
Defective thermostat Replace thermostat)
Indicator of water temperature Loose radiator filler cap (high Tighten cap or replace packing
gauge is in red range on right altitude operation)
side of gauge Defective water temperature Replace water temperature gauge)
gauge
Indicator of water temperature l Defective thermostat l Replace thermostat

gauge is in white range on left l Defective water temperature l Replace water temperature gauge
side of gauge gauge
Engine does not start when Lack of fuel l Add fuel, see CHECK BEFORE
starting motor is turned STARTING
Air in fuel system l Repair place where air is sucked in
Defective fuel injection pump or (e Replace pump or nozzle)
nozzle
Starting motor cranks engine
sluggishly
Glow signal does not glow red
Defective compression
I- See ELECTRICAL SYSTEM
o Defective valve clearance (0 Adjust valve clearance)
Exhaust gas is white or blue l Too much oil in oil pan l Add oil to specified level, see CHECK
BEFORE STARTING
l Improper fuel l Change to specified fuel
Exhaust gas occasionally turns l Clogged air cleaner element l Clean or replace, see WHEN REQUIRED
black l Defective nozzle (o Replace nozzle)
l Defective compression (o Adjust valve clearance)
Combustion noise occasionally l Defective nozzle (o Replace nozzle)

makes breathing sound
Abnormal noise generated l Low grade fuel being used l Change to specified fuel
(combustion or mechanical) l Overheating l See item “Indicator of water temperature
gauge is in red range on right side of
gauge”.
l Damage inside muffler (o Replace muffler)
l Excessive valve clearance (o Adjust valve clearance)
2-69
2-70
3
b
2
I
m
2
17. GUIDES TO MAINTENANCE
Do not carry out any inspection and maintenance operation that is not given in this manual.
Perform maintenance work on hard, flat ground.
Check service meter

Check the service meter reading every day to see if the time has come for any necessary maintenance
to be carried ‘out.
Komatsu genuine replacement parts:

Use Komatsu genuine parts specified in the parts list as replacement parts.
Komatsu genuine oils:

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for
ambient temperature.
Clean oil and grease:

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

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

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

When replacing the oil or the filter, check it for metal chips, foreign matter, etc.
Fuel strainer:
If your machine is equipped with a fuel strainer, do not remove it while fueling.
Oil change:
Check or change oils in the places where dust is scarce to keep foreign materials away from oils.
Warning tag:
Attach the warning tag to the starting switch or other appropriate control lever to avoid someone who
is not aware of the circumstances from starting the engine.
3-2
17. GUIDES TO MAINTENANCE
Obey precautions:
During the operation, always obey the precautions on the safety label stuck to the machine.
Welding instructions:
l Turn off the engine starting switch.
l Do not apply more than 200 V continuously.
l Connect grounding the cable within 1 m from the area to be welded.
l Avoid seals or bearings from being between the area to be welded and the position of grounding
point.
Fire prevention:
Use nonflammable cleaner or light oil for cleaning parts. Keep flame or cigerette light away from light
oil.
Clamp faces:
When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings and gaskets with
new ones. Be sure to fit O-rings and gaskets when assembling.
Objects in your pockets:

Keep your pockets free of loose objects which can fall out and drop into the machinery; especially when
you work on the machinety while bending over it.
Checking undercarriage:
When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and
damage in bolts and nuts. Loosen the track tension a little when working in such areas.
Cleaning machine:
l Do not direct a high-pressure jet directly at the radiator.
l Do not splash water over the electrical equipment.
Pre-and post-work checks:

Before starting work in mud rain, snow or at seashore, check plugs and valves for tightness.
Wash the machine immediately after the work to protect components from rusting.
Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they
are submerged in water.
Dusty worksites:
When working at dusty worksites, do as follows:
0 Check the air cleaner for clogging more frequently. Clean the air cleaner at shorter intervals than
specified.
l Clean the radiator core frequently to avoid clogging.
l Clean and replace the fuel filter frequently.
0 Clean electrical components, especially the starting motor and alternator, to avoid accumulation of
dust.
Avoid mixing oils:

Never mix oils of different brands. If you have only oil which is a different brand from the one that is
used in the machine, do not add it but replace all the oil.
3-3
18. OUTLINES OF SERVICE
l Use Komatsu genuine parts for replacement.
l When changing or adding oil, do not use a different type of oil.
l Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as
shown in the table below.
Item I Kind of fluid
SAE 15W-40
Engine oil pan
API classification CD
Power train case

(including torque
SAE 30
converter case) API classification CD
Steering clutch case
Final drive case
SAE 1OW
Hydraulic tank API classification CD
ASTM D975 No. 2

(However, ASTM D975 No. 1 is
Fuel tank
used for the winter season
(October to March))
Komatsu Super Coolant

Radiator (AF-ACL) 41% added to water
18.1 OUTLINE OF OIL, FUEL, COOLANT
18.1.1 OIL
Oil is used in the engine and work equipment under extremely severe conditions (high temperature,
high pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and
Maintenance Manual. Even if the oil is not dirty, always replace the oil after the specified interval.
Oil corresponds to blood in the human body, so always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from getting in.
The majority of problems with machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit.
In such cases, please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you to have an analysis made of the oil periodically to check the condition of the
machine. For those who wish to use this service, please contact your Komatsu distributor.
3-4
18.1.2 FUEL
l The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work
properly.
l Be extremely careful not to let impurities get in when storing or adding fuel.
l Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature
below -lS”C), so it is necessary to change to a fuel that matches the temperature.
l To prevent the moisture in the air from condensing and forming water inside the fuel tank, always
fill the fuel tank after completing the day’s work.
l Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment
and water from the fuel tank.
l If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from
the circuit.
18.1.3 COOLANT
River water contains large amounts of calcium and other impurities, so if it is used, scale will stick
to the engine and radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.
When using anti-freeze, always observe the precautions given in the Operation and Maintenance
Manual.
Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine
is shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as
it is even in hot areas.
Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.
The proportion of anti-freeze to water differs according to the ambient temperature.
For details of the mixing proportions, see “24.1.1 CLEAN INSIDE OF COOLING SYSTEM”.
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating and will also cause problems with corrosion from
the air in the coolant.
18.1.4 GREASE
l Grease is used to prevent twisting and noise at the joints.

l The nipples not included in the maintenance section are nipples for overhaul, so they do not need
grease.
If any part becomes stiff after being used for a long time, add grease.
l Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe
off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating
parts.
3-5
18.1.5 STORING OIL AND FUEL
l Keep indoors to prevent any water, dirt, or other impurities from getting in.
l When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum
can is at the side. (To prevent moisture from being sucked in)
If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures
to protect them.
l To prevent any change in quality during long-term storage, be sure to use in the order of first in -
first out (use the oldest oil or fuel first).
18.1.6 FILTERS
l Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from
entering important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, it is necessary to consider replacing the filters at
shorter intervals according to the oil and fuel (sulfur content) being used.
l Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
l When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles
are found, please contact your Komatsu distributor.
l Do not open packs of spare filters until just before they are to be used.
l Always use Komatsu genuine filters.
18.2 RELATING TO ELECTRIC SYSTEM
l If the wiring gets wet or the insulation is damaged, the electric system leaks and this could result
in hazardous malfunction of the machine.
l Services relating to the electric system are (I) check of fan belt tension, (2) check of damage or wear
in the fan belt and (3) check of battery fluid level.
l Never remove or disassemble any electric components installed in the machine.
l Never install any electric components other than these specified by Komatsu.
l Be careful to keep the electric system free of water when washing the machine or when it rains.
l When working on the seashore, carefully clean the electric system to prevent corrosion.
l Never connect any optional power source to the fuse, starting switch, battery relay, etc.
3-6
19. WEAR PARTS LIST
Wear parts such as the filter element, cutting edge, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
The parts in parentheses are to be replaced at the same time.
Replacement
Item Part No: Part Name Q’tv
frequency
Engine oil filter 600-211-1231 Cartridge 1

Every 250 hours
Power train/ 175-49- 11580 Element 2 service
steering oil filter (07000-02115) (O-ring) (2)
Fuel filter 600-3 11-8293 Cartridge Every 500 hours

service
141-60-18270 Cartridge 1
Hydraulic oil filter
(07000-15145) (O-ring) (1) Every 1000 hours
service
Corrosion resistor 600-41 l-l 151 Cartridge
I I ’ I
600-8 I-7032 Element ass’y 1

Air cleaner -
600-181-4300 Outer element ass’y 1
145-70-44180 Tooth 9
Bucket tooth (145-70-44120) (Bolt) (27)
(I 45-70-44130) (Nut) (27)
Electrical intake air heater 6150-11-4820 Gasket

I 12.1 -
NOTICE
When handling parts that weight more than 20 kg, remember that they are heavy objects, and take
the necessary care.
3-7
20. USE OF FUEL, COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
RESERVOIR
KIND OF
FLUID 22 -4
AMBIENT
14 32
TEMPERATURE
50 68
r
86 104’F
CAPACITY
Specified Refill
30 -20 -10 0 10 20 30 4O’C
32 Q 26 Q
Engine oil pan 8.3 US gal 6.7 US gal
7.0 UK gal 5.7 UK gal
Power train case 52 Q 47 Q

(Frl.e:;)rque con- 13.5 US gal 12.2 US gal
Engine oil
75 Q 73 Q
Steering cluth case 19.5 US gal 18.9 US gal
23 Q 23 Q
Final drive case 5.9 US gal 5.9 US gal
(each) 5.0 UK gal 5.0 UK gal
135 Q 63 Q
Hydraulic tank 35.1 US gal 16.4 US gal
400 Q
Fuel tank Diesel fuel 104 US gal
88 UK gal
65 Q
Cooling system Water Add antifreeze 16.9 US gal
(incl. sub-tank) 14.3 UK gal
J
% ASTM D975 No. 1
3-8
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
REMARK
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%.
Above 1.0% l/4 of regular interval
When starting the engine in an atmospheric temperature of lower than O’C, be sure to use engine
oil of SAEIOW, SAEIOW-30 and SAE15W-40, even though an atmospheric temperature goes up to
10°C more or less in the day time.
Use API classification CD as engine oil and if API classification CC, reduce the engine oil change
interval to half.
There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, ISW-401, but be
sure to add single grade oil that matches the temperature in the table.
We recommend Komatsu genuine oil which has been specifically formulated and approved for use
in engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
3-9
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Engine Oil
Anti-freeze
[CD or CEI
Coolant
SAEIOW, 30, 40 Gear Oil Grease
No. Supplier [Ethylene Glycol
1ow30, 15w40 [GL-4 or GL-51 [Lithium-Base]
Base1
(The 15W40 oil SAEBO, 90, 140 NLGI No. 2
Permanent Type
marked * is CE.)
EOI O-CD AF-ACL

EOBO-CD GO90 G2-LI AF-PTL
1 KOMATSU
EOIO-30CD GO140 G2-LI-S AF-PT (Winter, one
EOI 5-40CD season type:
Diesel sigma S
Super dieselmulti-
2 AGIP Rotra MP GR MU/EP
grade
*Sigma turbo
Multi-purpose gear RYKON prenium

3 AMOCO *Amoco 300
oil grease
Litholine HEP 2 -
4 ARC0 *Arcofleet 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~Y Anti-freeze
Spheerol EPL2
CRD HYP~Y B
HYP~Y C
8 CHEVRON *Del0 400 Universal gear Ultra-duty grease 2
Universal gear -
9 CONOCO *Fleet motor oil Super-sta grease
lubricant
Multiperformance 3C - Tranself EP
10 ELF Glacelf
Performance 3C Tranself EP type 2
Essolube D3
“Essolube XD-3
EXXON Gear oil GP
*EssoIube XD-3 Extra Beacon EP2 All season coolant
” (ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifreeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2

Mobilube GX
13 MOBIL *Delvac super Mobilgrease 77
Mobilube HD
1ow-30, 15w-40 Mobilgrease special
3-10
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATU
RE
Engine Oil
[CD or CEI Anti-freeze
SAE 1OW, 30, 40 Gear Oil Coolant
rl0. Supplier Grease
1ow30, 15w40 [GL-4 or GL-51 [Ethylene Glycol
[Lithium-Base1
(The 15W40 oil SAE80, 90, 140 Base1
NLGI No. 2
marked * is CE.) Permanent Type
Multi-purpose white
*Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White - bearing summer coolant
grease
15 / PETROFINAI FINA kappa TD / ~~~~ $~~~~ /E / FINA marson EPL2 / FINA tamidor
16 1 SHELL Spirax EP
j Rimula X Alvania EP grease
Spirax heavy duty
Sunoco ultra prestige Sunoco antifreeze

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

18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total transmission Multis EP2 Antigel/antifreeze
*Rubia X
TM
20 UNION *Guard01 MP gear lube LS Unoba EP
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C
3-11
21. iTl&tDARD TIGHTENING TORQUES FOR BOLTS AND
21.1 INTRODUCTION OF NECESSARY TOOLS
The following tools are needed when carrying out maintenance.
No. Name of tool Part No. Remarks
1 Wrench set 09000-30006 Applicable width across flats (S1 - S2)

8 mm - 10 mm, 12 mm - 14 mm
13 mm - 17 mm, 19 mm - 22 mm
s2
24 mm - 27 mm, 30 mm - 32 mm
2 Screwdriver 09033-00190 Interchangeable flat-head and cross-head type
3 Socket wrench set 09020-10285 Applicable width across flats

10 mm, 13 mm
14 mm, 17 mm
19 mm, 22 mm, 24 mm,
Extension, Handle
4 Filter wrench 090 1g-08035 For filter cartridges
5 Socket 09084-00915
6 Grease pump 07952-80002 For greasing work
7 Grease cartridge 07950-90403 (Lithium base grease, 400 g)
If any of the above tools are broken, please order them from your Komatsu distributor.
Whennot using the tools, always put them in the tool box on the inside of the battery inspection
cover on the left side of the machine.
3-12
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
21.2 TORQUE LIST

Unless otherwise specified, tighten the metric bolts and nuts to
the torque shown in the table.
The tightening torque is determined by the width across the flats
@ of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu
genuine part of the same size as the part that was replaced.
Nm (newton meter): INm e 0.1 kgm
+ 0.74 Ibft
Thread diameter Width across

of bolt (mm) flat (mm) b
AD054300
(a) (b)
I Nm km lbft
6 10 13.2 2 1.4 1.35 f 0.15 9.73 ” 1.03

8 13 31.4 -c 2.9 3.2 ‘c 0.3 23.2 2 2.1
10 17 65.7 2 6.8 6.7 2 0.7 48.5 f 5.0
12 19 112 + 9.8 11.5 r 1.0 82.6 + 7.2
14 22 177 * 19 18.0 k 2.0 131 f 14
16 24 279 * 29 28.5 2 3 t 206 2 21

18 27 383 2 39 39 f 3 282 it 29
20 30 549 + 58 56 2 6 405 + 43
22 32 745 2 78 76 2 8 549 2 58
24 36 927 t 98 94.5 * IO 684 2 72
t
27 41 1320 r 140 135 + 15 973 f 100
30 46 1720 r 190 175 2 20 1270 2 140
33 50 2210 2 240 225 2 25 1630 2 180
36 55 2750 r 290 280 3 30 2030 r 210
39 60 3280 k 340 335 rc_35 2420 r 250
NOTICE
When tightening panels or other parts having tightening fix-
tures made of plastic, be careful not to use excessive tightening
torque: doing so will damage the plastic parts.
3-13
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
To ensure safety at all times when operating or driving the machine, the user of the machine must
always carry out periodic maintenance. In addition, to further improve safety, the user should also carry
out periodic replacement of the parts given in the table. These parts are particularly closely connected
to safety and fire prevention.
With these parts, the material changes as time passed, or they easily wear or deteriorate. However,
it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always
be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that
they always maintain their function completely.
However, if these parts show any abnormality before the replacement interval has passed, they
should be repaired or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at
the same as the hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same
time.
Ask your Komatsu distributor to replace the critical parts.
No. Safety critical parts for periodic replacement O’ty Replacement interval
1 Fuel hose (Between fuel filter and injection pump) 2
2 Fuel hose (Between strainer and injection pump) 1
3 Fuel hose (Between injection pump and connector) 1
4 Fuel hose (Between connector and fuel tank) 1

I I
5 1 Spill hose (Betw een nozzle and connector) 1
II
6 Spill hose (Between connector and fuel tank) 1

Every 2 years or 4000 hours,
7 Turbocharger lubricating hose 1 whichever comes sooner
Hose between torque converter relief valve and

8 1
transmission control valve I/
Hose between transmission pump and
9 1
transmission filter I I
1o Hose between transmission filter and
1
transmission control valve I I
between torque converter relief valve and
toraue converter I I 1
12 Hose between steering oil filter and steering

2
relief valve I I
13 Seat belt I 1 I Replace every 3 years
3-14
23. MAINTENANCE SCHEDULE CHART
23.1 MAINTENANCE SCHEDULE CHART
SERVICE ITEM PAGE
INITIAL 250 HOURS SERVICE (only after the first 250 hours)
Replacement of fuel filter cartridge 3-18

Replacement of transmikssion case oil (including torque converter case oil)
3-18
and cleaninu of strainer
Replacement of steering clutch case oil 3-18
Replacement of final drive case oil 3-18
Replacement of hydraulic oil and hydraulic oil filter cartridge 3-18
Replacement of oil in engine oil pan and engine oil filter cartridge 3-18
Check of engine valve clearance 3-18
WHEN REQUIRED
Clean inside of cooling system 3-19
Check, clean and replace air cleaner element 3-22
Check track tension 3-24
Check electrical intake air heater 3-25
Adjustment of steering brake 3-26
Adjustment of clearance of idler 3-27
Adjustment of work equipment 3-27
Replacement of bucket tooth 3-28
CHECK BEFORE STARTING
Check and refill of coolant 3-29
Check fuel level 3-29
Check oil level in engine oil pan, add oil 3-30
Check oil level in transmission case (including torque converter case), add oil 3-31
Check oil level in steering clutch case, add oil 3-32
Check dust indicator 3-33
Check steering pedal travel 3-33
Check that lamps light up 3-34
Check horn sound 3-34
Check backup alarm sound (option) 3-35
Check seat belt for wear or damage (option) 3-35
3-15
SERVICE ITEM PAGE
EVERY 50 HOURS SERVICE
Supply of grease to bucket pin (4 places) 3-36
Supply of grease to dump cylinder shaft (4 places) 3-36
Supply of grease to lift arm support shaft (2 places) 3-36
Supply of grease to lift cylinder shaft (4 places) 3-36
Draining water and sediment from fuel tank 3-37
Supply of grease to tilt lever pin (4 places) 3-38
Supply of grease to equalizer bar shaft (I place) 3-38
Check oil level in final drive case, add oil 3-39
Check and supply of hydraulic tank oil 3-39
Replace oil in engine oil pan and engine oil filter cartridge 3-40
Replace transmission and steering oil filter 3-41
Clean strainer at bottom of fuel tank 3-42
Check battery fluid level 3-42
Check and adjust fan belt tension 3-43
Check and retighten track shoe bolts 3-44
Replace fuel filter cartridge 3-45
Cleaning of steering clutch case breather 3-47
Cleaning of transmission case breather 3-47
Cleaning of final drive case breather
Clean and check radiator fin 3-47
Replace corrosion resistor cartridge 3-48
Supply of grease to diagonal brace (2 places) 3-48
Supply of grease to universal joint (2 places) 3-48
Replace oil in transmission case (including torque converter case) and clean strainer 3-49
Replace oil in steering clutch case and clean strainer 3-51
Replace oil in final drive case 3-52
Replace oil in hydraulic tank and hydraulic oil filter element
Check oil for undercarriage 3-54
3-16
SERVICE ITEM PAGE
EVERY 1000 HOURS SERVICE (continued)
Check clamping parts of turbocharger 3-54
Check turbocharger rotor for play 3-54
Supply of grease to steering pedal shaft (IO places) 3-55
Supply of grease to gear shift lever shaft (3 places) 3-55
Supply of grease to fuel control lever shaft (2 places) 3-56
Supply of grease to decelerator pedal shaft (3 places) 3-56
Supply of grease to bucket control lever shaft (3 places) 3-56
Clean engine breather element 3-57
Check alternator and starting motor 3-57
Check and adjust engine valve clearance 3-57
Clean and check turbocharger 3-57
Check vibration damper 3-57
Check water pump 3-58
3-17
24. SERVICE PROCEDURE
24.1 INITIAL 250 HOURS SERVICE
Carry out the following maintenance only after the first 250
hours.
l REPLACEMENT OF FUEL FILTER CARTRIDGE

l REPLACEMENT OF TRANSMISSION CASE OIL (INCLUDING
TORQUE CONVERTER CASE OIL) AND CLEANING OF STRAINER
l REPLACEMENT OF STEERING CLUTCH CASE OIL
l REPLACEMENT OF FINAL DRIVE CASE OIL
l REPLACEMENT OF HYDRAULIC OIL AND HYDRAULIC OIL FIL-
TER CARTRIDGE
l REPLACEMENT OF OIL IN ENGINE OIL PAN AND HYDRAULIC
OIL FILTER CARTRIDGE
l CHECK OF ENGINE VALVE CLEARANCE
For details of the method of replacing or maintaining, see the

section on EVERY 1000 HOURS and 2000 HOURS SERVICE.
3-18
24.2 WHEN REQUIRED
24.2.1 CLEAN INSIDE OF COOLING SYSTEM
a WARNING
Soon after the engine has been stopped, the coolant is hot
and can cause personal injury. Allow the engine to cool
before draining water.
Never be under the machine with the engine running. To
avoid serious injury, .always stop the engine before being
under the machine to open the drain valve.
Never remove the radiator cap when the engine is at operat-
ing temperature. At operating temperature, the coolant is
under pressure. Steam blowing up from the radiator could
cause personal injury. Allow the engine to cool until the
radiator filler cap is cool enough to touch with your hand.
Remove the filler cap slowly to relieve pressure.
When removing drain plug, avoid pouring coolant on your-
self.
Antifreeze is flammable, so keep it away from any flame.
l Clean the inside of the cooling system, change the coolant and
replace the corrosion resistor according to the table below.
Cleaning inside of
Replacing corrosion
Kind of coolant cooling system and
resistor
changing coolant
Permanent type antifreeze Every year (autumn) or

(All season type) every 2000 hours
I whichever comes first
Non permanent type Every 6 months (spring, Every 1000 hours and
antifreeze containing autumn) when cleaning the inside
ethylene glycol (Winter, (Drain antifreeze in spring, of the cooling system and
one season type) add antifreeze in autumn) when changing coolant
Every 6 months or every

When not using antifreeze 1000 hours whichever
comes first
3-19
0 Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type
antifreeze, use an antifreeze containing ethylene glycol.
l Stop the machine on level ground when cleaning or changing

the coolant.
l When deciding the ratio of antifreeze to water, check the lowest

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

mixing proportions.
l Use city water for the cooling water.

If river water, well water or other such water supply must be
used, contact your Komatsu distributor.
1. Stop the engine and close corrosion resistor levers @ (2 places).
AE20521B
3-20
2. Slowly turn radiator cap @ to remove it.
3. Prepare a container to receive the coolant mixture, then open

drain valve @ on the underside of the radiator and drain plug @
on the oil cooler to drain the coolant.
4. After draining the coolant, close drain valve @ and drain plug 0,
then supply city water to the radiator. I lo \
AM143020
5. If the radiator becomes full of water, open drain valve @ and

drain plug 0, then start and run the engine idle at a low speed.
While the engine is running idle at a low speed, keep supplying
water for 10 minutes.
Adjust the supply rate and draining rate so that the radiator is
kept full of water, and take care that the water supply hose will
not come off the water filler of the radiator while cleaning the
radiator.
AM143030
6. After cleaning the radiator, stop the engine and open drain valve
@ and drain plug @ to drain the water, then close them.
7. After draining the water, wash the inside of the radiator with
detergent. Follow the washing instructions of the detergent.
8. After washing the radiator, open drain valve @ and drain plug
@to drain the water. Close the valve and plug and supply water
up to near the water filler.
9. If the water is filled up to near the water filter, open drain valve
@ and drain plug @ and start and run the engine idle at a low
speed until clear water flows up.
Adjust the supply rate and draining rate so that the radiator is
kept full of water.
IO. If clean water flows out, stop the engine and close drain valve
@ and drain plug 0.
11. Replace the corrosion resistor and open levers @ (2 places).

For the replacement procedure of the corrosion resistor, see
“24.7.1 REPLACE CORROSION RESISTOR CARTRIDGE”.
12. Supply city water until it spills out of the water filler.
13. Run the engine idle at a low speed for five minutes to bleed air
mixed in the cooling water, then run idle it at a high speed for
5 minutes. (Keep the water filler cap removed during this period.)
14. Stop the engine and wait for about 3 minutes. Supply city water
up to near the oil filler, then close the cap.
3-21
24.2.2 CHECK, CLEAN AND REPLACE AIR CLEANER

ELEMENT
Never clean or replace the air cleaner element with the engine
l When using pressure air to clean the element wear safety

glasses or goggles to protect the eyes.
CHECKING
Whenever the red piston in dust indicator @ appears, clean the
air cleaner element.
CLEANING AND REPLACEMENT OF OUTER CYLINDER ELEMENT

1. Remove bolt @ to remove clamp 0. Remove cover 0, then
remove the wing nut in it, and remove the outer cylinder ele-
ment.
2. Clean the inside of the body and cover.
3. Blow dry compressed air (68.6 MPa (7 kg/cm*) maximum) against

the inside of the element along the pleats. Then, blow against
outside along the pleats, then against inside again.
1) Remove one seal each time the element is cleaned.

2) Replace the outer cylinder element after cleaning it 6 times
or after one year. When replacing it, replace the inner cylin-
der element, too. ADO53020
3) Even if the outer cylinder element has not been cleaned 6

times yet, if the dust indicator indicates red just after clean-
ing it, replace both outer and inner cylinder elements.
4) Check the inner cylinder element clamping nut for looseness,
and retighten it if necessary.
5) If seal washer @ is damaged or the threads of wing nut @
are damaged, replace them.
6) Remove evacuator valve @) and clean it with compressed air.
Then, install it again.
NOTICE
If small holes or thinner parts are found on the element when
it is checked with an electric bulb after cleaning and drying, replace
the element.
Do not use an element whose folds or gasket or seal are
damaged.
When cleaning the element, do not hit it or beat it against
something.
AD053040
4. Install the cleaned element, then install cover 0.
REPLACEMENT OF INNER CYLINDER ELEMENT
1. Remove the cover and outer cylinder element, then remove the
inner cylinder element.
2. Cover the air connector opening (outlet side) with clean cloth or
cloth tape.
3. Clean the inside of the body, them remove the cover fitted in
Step 2 above.
4. Install a new inner cylinder element to the cylinder and tighten

the nut.
Do not clean and reuse the inner cylinder element.
5. Install outer element.
6. After replacing the element, return the red piston of the dust
indicator.
3-23
24.2.3 CHECK TRACK TENSION

The wear of pins and bushings on the undercarriage will vary
with the working conditions and soil properties. It is thus necessary
to continually inspect the track tension so as to maintain the stand-
ard tension.
Carry out the check and adjustment under the same conditions
as when operating (on jobsites where the track becomes clogged
with mud, measure with the track clogged with mud).
INSPECTION
Stop the machine on level ground (stop with the transmission in
FORWARD without applying the brake). Then place a straight bar on
the track shoes between the carrier roller and the idler as shown in
the figure, and measure the clearance between the bar and the
grouser at the midpoint. If the clearance is 20 - 30 mm (0.8 - 1.2 in),
the tension is standard.
If the track tension is not at the standard value, adjust it in the
AN143080
following manner.
ADJUSTMENT
-a WARNING
Grease inside the adjusting mechanism is under high pressure.
Grease coming from lubricator @ under pressure can penetrate
the body causing injury or death. For this reason, do not loosen
lubricator @ more than one turn. Do not loosen any part other N
2- AM143090
than lubricator 0. Furthermore, do not bring your face in front
of the grease fitting.
If the track tension is not relieved by this procedure, please
contact your Komatsu distributor.
0 When increasing tension

1. Pump in grease through the grease fitting 0 with a grease
pump.
2. To check that the correct tension has been achieved, move the
machine backwards and forwards.
3. Check the track tension again, and if the tension is not correct,
adjust it again.
4. Continue to pump in grease until S becomes 0 mm. If the tension

is still loose, the pin and bushing are excessively worn, so they
must be either turned or replaced. Please contact your Komatsu
distributor.
‘s’- AM143100
3-24
l When loosening tension
a WARNING
It is extremely dangerous to release the grease by any method
except the procedure given below. If the track tension is not
relieved by this procedure, please contact your Komatsu dis-
tributor.
1. Loosen lubricator @ gradually to release the grease.
2. Turn lubricator 0 a maximum of one turn.
3. If the grease does not come out smoothly, move the machine
backwards and forwards a short distance.
4. Tighten lubricator 0.
5. To check that the correct tension has been achieved, move the
machine backwards and forwards.
6. Check the track tension again, and if the tension is not correct,
adjust it again.
24.2.4 CHECK ELECTRICAL INTAKE AIR HEATER

Before the cold season (once a year), ask one of our distribu-
tors for check of electrical intake air heater. Remove electrical intake
air heater @ from the engine intake manifold and check it for wire
breakage, dust, etc.
When installing the electrical heater after checking it, replace its
gasket with new one.
3-25
24.2.5 ADJUSTMENT OF STEERING BRAKE

When the stroke of the steering pedals is too long, the brake
lining may be worn. Adjust in this case according to the following
procedure.
INSPECTION
The standard stroke of each steering pedal is 127 - 191 mm (5.0
- 7.6 in). If the stroke is 192 mm (7.7 in) or longer, adjust it according
to the following procedure.
The standard clearance between the lining and drum is 0.3 mm
(0.012 in).
&
127-191 mm
(5. O-7. 6 in) AD,42268
ADJUSTING
1. Remove the rear cover, then remove brake inspection cover 0.
AN143130
2. Tighten adjustment nut @ (Tightening torque: 88.3 N-m (9 kgf.m,

19.8 Ibft)) to fit the lining to the drum (Confirm by pressing the
pedal).
3. Return adjustment nut @ about 1 and 5/6 turns, and confirm that
the standard stroke is obtained.
If the brake does not work normally after the above adjustment,
please contact your Komatsu distributor.
3-26
24.2.6 ADJUSTMENT OF CLEARANCE OF IDLER

The idler is moved by external forces, and the guide plate is worn
at this time.
If the guide plate is worn, the idler shakes or slants sideways or
the tracks come off or are worn unevenly. Accordingly, adjust the
clearance of the idler according to the following procedure.
ADJUSTMENT METHOD
1. Run the machine by 1 - 2 m (3.28’ - 6.56’) on a flat place, then
measure clearance A between the track frame and guide plate (4
places on both sides, inside and outside).
2. If clearance A is larger than 4 mm (0.16 in), loosen bolt @ and

remove one or more shims to adjust the clearance on each side
to 0.5 - 1 mm (0.02 - 0.04 in). The thickness of one shim is 0.6
mm (0.024 in).
Track frame AE,~3,5B
24.2.7 ADJUSTMENT OF WORK EQUIPMENT

The bucket can be stopped automatically at a desired height and
angle for each work with the boom kick-out device and bucket
positioner.
ADJUSTMENT OF KICK-OUT
1. Raise the bucket to the desired level, then stop the engine and
set the bucket control lever to RAISE position, then adjust the
kick-out as follows.
r
2. Loosen lock nut 0 and tighten bolt @ to stopper @ of the lift

cylinder, then tighten lock nut 0.
I
3. After adjusting the kick-out, start the engine and operate the
bucket control lever and confirm that the lever returns to HOLD
position automatically when the bucket rises to the desired level.
If bolt @ does not touch the stopper 0, adjust rod 0.
3-27
ADJUSTMENT OF POSITIONER
1. Lower the bucket to the ground and adjust it to the desired
digging angle, then stop the engine and adjust the positioner as
follows.
2. Remove switch cover 0.
3. Loosen bolt @ and adjust rod @I so that projection @ of rod @

will touch roller 0, then tighten bolt 0.
4. After adjusting the positioner, start the engine and operate the
bucket control lever and confirm that the lever returns to HOLD
position automatically when the bucket is set to the desired
digging angle. After confirmation, install the cover.
ANI
24.2.8 REPLACEMENT OF BUCKET TOOTH
A WARNING
It is dangerous for the work equipment to move by itself while
replacing the bucket tooth. Accordingly, set the work equip-
ment down and stop the engine, then apply the safety lock
lever.
If the bucket tooth is worn, replace it according to the following

procedure.
1. Raise the bucket to a proper level and support it with a block so

that it will not lower.
Level the bucket bottom.
2. Remove bolt @ and nut 0, then remove bucket tooth @ and

clean the fitting surface of the bucket.
3. Install a new tooth to the bucket.
Tightening torque of mounting bolt: 1180 N-m {I20 kgf.m, 264.6 But
Ibft}
After operating the machine for several hours, retighten the Cl43218
mounting bolts. I
3-28
24.3 CHECK BEFORE STARTING

24.3.1 CHECK AND REFILL COOLANT
A WARNING
Do not remove cap @while cooling water is hot. Hot water may
spout out.
When removing cap (ij, wait until the water temperature goes
down and release radiator pressure little by little by loosening
caps slowly, then remove the cap.
1. Open the top cover at the front part of the machine body.
2. Remove radiator cap @I and confirm that the coolant is filled up

to the neck of water filler. Refill new coolant, if necessary.
NOTICE
lf more coolant than usual is required, it may be leaking from
AM142210
somewhere. Check for leakage in this case.
24.3.2 CHECK FUEL LEVEL
A WARNING
When adding fuel, never let the fuel overflow. This may cause
a fire. If spilling fuel, thoroughly clean up any spillage.
1. Check the fuel level using fuel gauge 0.
2. After completing work, fill the fuel tank through oil filler port 0.
3. After adding fuel, tighten the cap securely.

Fuel capacity: 400 e (104 US gal, 88 UK gal)
NOTlCE
A clogged cap breather hole @ may stop the fuel flow to the
engine. Check it from time to time and clean.
AD054210
3-29
24.3.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
1. Open the upper cover at the front of the machine.
2. Remove dipstick @ and wipe the oil off with a cloth.
3. Insert dipstick @fully in the oil filler pipe, then take it out again.
0.
If the oil level is below the L mark, take out the dispstick and add
engine oil through oil filler 0.
I /I
drain plug, and check the oil level again.
1 ’ AD352340
6. If the oil level is correct, tighten the oil filler cap securely, insert
oil level gauge @ fully into the dipstick guide, then close the
upper cover.
REMARK
checking.
l If the machine is at an angle, make it horizontal before checking.
l When adding oil, remove the oil level gauge from the gauge
guide so that the air in the crank case will be released.
3-30
24.3.4 CHECK OIL LEVEL IN TRANSMISSION CASE

(INCLUDING TORQUE CONVERTER CASE), ADD OIL
1. Open the cover, remove dipstick 0, and wipe the oil off with a
cloth.
2. insert dipstick @fully in the oil filler pipe, then take it out again.

0.
0.
AD052340
drain plug 8, and check the oil level again.
5. If the oil level is correct, tighten the oil filler cap securely and
close the cover.
REMARK
l When stopping the engine, check the oil level.
checking.
3-31
24.3.5 CHECK OIL LEVEL IN STEERING CLUTCH CASE,

ADD OIL
When working on a slope of 25” or steeper, add engine oil up

to the H mark.
1. Remove dipstick 0, and wipe the oil off with a cloth.
2. insert dipstick @fully in the oil filler pipe, then take it out again.

0.
If the oil level is below the L mark, and engine oil through oil filler
0.
4. If the oil level is above the H mark, drai the excess engine oil
from drain plug 8, and check the oil level again.
5. If the oil level is correct, tighten the oil filler cap securely.
REMARK
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before check-
ing.
3-32
24.3.6 CHECK DUST INDICATOR

1. Check that the red piston has not appeared in the transparent
portion of dust indicator 0.
2. If the red piston has appeared, clean or replace the element 0

immediately.
For details of the method of cleaning the element, see “24.2
WHEN REQUIRED”.
II \\ AM142270
3. After checking, cleaning, and replacing, press the knob of dust

indicator @ to return the red piston to its original position.
ADO52091
24.3.7 CHECK STEERING PEDAL TRAVEL

1. Depress the brake pedal all the way until it stops.
2.
3.
The distance of travel at the center of the pedal (position in the
diagram on the right) should be 127 - 191 mm (5.0 - 7.6 in).
When this value exceeds 192 mm (7.7 in), or the brake fails to
work, please contact your Komatsu distributor for adjustment.
L’!kc 127-191 mm
(5. O-7. 6 in) AD,4226B
3-33
24.3.8 CHECK THAT LAMPS LIGHT UP
position. HEA,T OFF
AE214499
2. Confirm that the lamps light up by operating lamp switch 0.

OFF position: Lamps are turned off.
Position 1: Headlight and instrument lights are turned on. 2
Position 2: Headlight, instrument light, and rearworking lamps 1
are turned on.
OFF
If any of the lamps does not light up, ask our distributor to
inspect the machine.
AD14203B
24.3.9 CHECK HORN SOUND
1. Insert the key into starting switch Q) and turn the key to the ON
position.
2. Push the horn switch @ and check that the horn sounds.
AH142040
3-34
24.3.10 CHECK BACKUP ALARM SOUND (OPTION)

\QL2
position.
AE21449B
2. Set gear shift lever @ to the rear position.

The buzzer must sound immediately. It keeps sounding until the N
gear shift lever is set to “NEUTRAL” or “FORWARD” position.

Rl
I - AD205110
24.3.11 CHECK SEAT BELT FOR WEAR OR DAMAGE

(OPTION)
Check the belt and mounting clamps, and if they are worn or
damaged, replace the seat belt.
3-35
24.4 EVERY 50 HOURS SERVICE

24.4.1 SUPPLY OF GREASE
1. Lower the bucket to the ground horizontally, then stop the

engine.
2. Supply grease to the grease fittings indicated by the arrows with

a grease pump.
1. Bucket pin (4 places)
-AN143220
2. Dump cylinder shaft (4 places)
230
3. Lift arm support shaft (2 places)
4. Lift cylinder shaft (4 places)
3. After supplying new grease, wipe off the used and projected
grease.
3-36
24.4.2 DRAIN WATER AND SEDIMENT FROM FUEL TANK 1 1

1. Drain water and sediment from the fuel tank before starting the
machine.
-
2. Prepare a container to receive water and sediment.
3. Open valve @) on the underside of the tank to drain the sediment

and water together with fuel. Take care not get soaked with fuel
at this time.
4. When only clear fuel flows out, close drain valve 0.
3-37
Maintenance for every 50 hours service should be carried out at

the same time.
24.5.1 SUPPLY GREASE
1. When supplying grease to the tilt lever pin, lower the bucket to
the ground horizontally, then stop the engine.
2. When supplying grease to the equalizer bar, raise the lift arm and
apply the lift arm stay, then stop the engine.

a grease pump.
1. Tilt lever pin (4 places)
2. Equalizer bar shaft (I place)
4. After supplying new grease, wipe off the used and projected
grease.
3-38
24.5.2 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
-------A WARNING v
The oil temperature is high just after the engine is stopped. Wait
until the oil temperature lowers before starting the following
work.
1. Remove both plugs 0. If the oil is filled up to near the bottom

AN143290
of each plug hole, the oil is sufficient.
2. If the oil level is low, add engine oil through oil filler (E).
24.5.3 CHECK AND SUPPLY OF HYDRAULIC TANK OIL
I A WARNING
When removing the oil filler cap, release internal pressure
little by little by loosening it slowly, then remove it, other-
wise the oil may spout out.
If oil is supplied more than the H mark, stop the engine and
wait until the hydraulic oil is cooled, then discharge excessive
oil through the drain plug.
NOTlCE
Do not refill oil more than the H mark. If it is over-supplied, the
hydraulic circuit may be damaged or it may spurt out.
1. Lower the bucket to the ground horizontally, then stop the

engine and wait for about five minutes. The oil level should be
between the top and bottom of the red circle in sight gauge 0.
2. If the oil level is below the bottom of the red circle, add engine
oil through oil filler 0.
3-39
24.5.4 REPLACE OIL IN ENGINE OIL PAN AND ENGINE
OIL FILTER CARTRIDGE
the engine, since each

part is still hot. Wait until the oil is cooled.
0 Container to receive 26 !Z (6.7 US gal,

used oil: 5.7 UK gal)
minimum
0 Replacement oil: 26 e (6.7 US gal, 5.7 UK gal)
0 Prepare socket wrench and filter wrench.
1. Remove the undercover of the machine body and place a con-

tainer to receive used oil just under the drain plug.
2. Remove drain plug @ slowly, taking care not to get soaked with
oil, and loosen valve @ to drain oil.
3. Check the drained oil. If it contains metal chips and foreign \

matter, please contact your Komatsu distributor.
4. Install drain plug 8.
5. Turn filter cartridge @to the left with the filter wrench to remove
it. If the engine has been operated, wait about 10 minutes, since
\
much oil flows out.
6. Clean the filter stand and fill the new cartridge with engine oil.
Apply engine oil (or grease) to the packing of the new filter
cartridge and install it.
7. After the packing surface touches the filter stand, turn the
cartridge further by 3/4 - 1 turn.
8. After replacing the filter cartridge, supply engine oil through oil
filler @ up to between H and L marks of the oil level gauge.
When supplying oil, take care not to splash it over the alternator.
9. Run the engine idle at a low speed for a while, then stop it.
Referring to “24.3 CHECK BEFORE STARTING”, confirm that the
AM143350
oil level is between the H and L marks of the oil level gauge.
Even if the machine has not been operated for 500 hours, the oil
and filter cartridge must be replaced when the machine has been
operated for 6 months.
In the same way, even if the machine has not been operated for 6
months, the oil and filter cartridge must be replaced when the
machine has been operated for 500 hours.
3-40
24.5.5 REPLACE TRANSMISSION AND STEERING OIL

FILTER ELEMENT
1. Raise the lift arm and apply the lift arm stay, then stop the
engine.
2. Set the safety lever of the bucket control lever to LOCK position.
3. Remove bolts @) of the filter case in the left-hand side frame,

then remove covers 0.
L
iL\\m\\ \\ \ \\\ -AM143360
4. Take out filter elements @ and clean the inside of the case and
the parts taken out. Install a new filter element and fill it with oil,
then install covers 0.
5. Start the engine and loosen air bleed plug @to let oil flow until
bubbles do not come out any more, then tighten the plug 0.
6. Start the engine and set the safety lever of the bucket control
lever to the FREE position, then raise the lift arm a little.
Remove the lift arm stay and lower the bucket to the ground
horizontally.
3-41
24.5.6 CLEAN STRAINER AT BOlTOM OF FUEL TANK

1. Close valve @ on underside of the fuel tank and remove cap 0,
then clean strainer and strainer case.
REMARK
Since the strainer is fixed to cap @ by brazing, take out them
together.
24.5.7 CHECK BAlTERY FLUID LEVEL

Check the battery fluid level before operating the machine.
WARNING
l Since the battery produces combustible gas, do not bring fire
l Battery fluid is dangerous!. Take special care that it does not

get in the eyes or on the skin. If it does, wash it away with
much water, and immediately call doctor.
1. Open the cover on the left side of the operator’s seat.
2. Remove cap @ and check the fluid level. If the fluid level is lower
than the UPPER LEVEL line, add distilled water. Do not add
distilled water more than the UPPER LEVEL. If so much is added,
leakage or fire may occur. If the battery fluid has spilt, add dilute
sulfuric acid.
3. Clean the vent of each battery cap, then tighten it securely. Keep
the battery top clean and wipe it with wet cloth.
REMARK
In the cold season, add distilled water before starting the work
on the next day, to prevent it from freezing.
3-42
24.5.8 CHECK AND ADJUST FAN BELT TENSION
CHECK
Push the intermediate point between the alternator and fan
pulley with the thumb (About 58.8 N (6 kgf, 13.2 Ibft)). It should be
deflected by 13 mm (0.52 in).
ApDrox 13mm (0.52in) Fan

PUI IY
/
_c
Alternator
PUIIY
?I
Crankshaft PUIIY AD143428
ADJUSTMENT
1. Insert a claw bar between alternator @ and cylinder block, and
fix it to alternator 0. When fixing the claw bar, insert a wood
liner between it and alternator @ so that the latter will not be
damaged.
2. Loosen bolt and nut 0 and 0.
3. Move alternator @ with the claw bar so that the belt will be
deflected about 13 mm (0.52 in) (About 58.8 N (6 kgf, 13.2 Ibft)).
4. Tighten bolt and nut 0 and @ to secure alternator 0.
5. Check each pulley for damage and V-grooves and V-belt for
wear. Particularly, check to see if the V-belt touches the bottom
of any V-groove.
6. If the belt is lengthened eliminate the adjustment allowance or

it has any cut or crack, replace it.
7. If the belt is replaced, adjust its tension again after one-hour

operation.
3-43
24.5.9 CHECK AND RETIGHTEN TRACK SHOE BOLTS

If the machine is operated with track shoe bolts @ loosened, the
latter will be broken. Accordingly, if any track shoe bolt is loosened,
retighten it to 785 + 78.5 N-m (80 + 8 kgf.m).
Tightening order
Tighten the track shoe bolts in the order shown at right.
3-44
Maintenance for every 50 and 250 hours service should be

carried out at the same time.
24.6.1 REPLACE FUEL FILTER CARTRIDGE
a WARNING
l Do not replace the filter just after stopping the engine, since
each part is still hot. ‘Wait until each part is cooled.
l Do not bring fire near the machine.
Prepare the filter wrench and a oil receiving container
engine.
3. Close fuel feed valve @ on under side of the fuel tank.
4. Place a container to receive used fuel just under the filter

cartridge.
5. Turn filter cartridge @ counterclockwise with the filter wrench to

remove it.
6. Clean the filter stand and fill the new cartridge with fuel. Apply
engine oil to the packing of the new filter cartridge and install it
to the filter stand.
7. After the packing surface touches the sealing surface of the filter
stand, turn the cartridge further by 2/3 turns.
If the filter cartridge is tightened too strongly, the packing will be

damaged and fuel will leak. If it is too loose, however, fuel will leak
through the gap of the packing. Accordingly, be sure to observe the
tightening angle.
8. After replacing filter cartridge 0, loosen air bleed plug 0.
3-45
9. Loosen the knob of feed pump @ and move it up and down to

let fuel flows out through air bleed plug @ until bubbles do not
come out any more.
10. Tighten air bleed plug @ and push in and tighten the knob of the
feed pump @.
11. Wipe off all spilt fuel with a cloth.
12. After replacing the filter cartridge, start the engine and check the
filter seal for fuel leakage. If any fuel leaks, check and adjust the
tightening condition of the filter cartridge. If fuel still leaks,
remove the filter cartridge by performing the procedures 4 and
5, and check the packing for damage and foreign matters. If the
packing is damaged or any foreign matter is caught in it, replace
the cartridge and repeat procedures 6 through 10.
13. Set the safety lever of the bucket control lever to the FREE
position, then raise the lift arm a little.
horizontally.
3-46
24.6.2 CLEAN BREATHER

Remove the breather and wash it in clean light oil.
1. Steering clutch case breather (I place)
2. Transmission case breather (I place)

Since the breather is a part of the oil filler cap, wash them
together.
3. Final drive case breather (2 places)
24.6.3 CLEAN AND CHECK RADIATOR FINS
&h WARNING
Compressed air, steam and water can cause injury. Be sure to
put on protective goggles, mask, safety shoes, etc.
1. Remove the bolts, then open the radiator grill.
2. Blow off sticking mud, dust, leaves, etc. from the radiator fins.
Steam or water may be used instead of compressed air.
3. Check the rubber hoses for cracking and brittleness, and replace
them if necessary. Check the hose clamps for looseness.
3-47
Maintenance for every 50,250 and 500 hours should be carried
out at the same time.
24.7.1 REPLACE CORROSION RESISTOR CARTRIDGE
a WARNING
If you replace the corrosion resistor cartridge just after stopping
the engine, since the cooling water is hot. Wait until the engine
is cooled.
1. Close levers @ (2 places) above the corrosion resistor.
2. Turn filter cartridge @to the left with the filter wrench to remove
it.
3. Clean the filter stand and apply engine oil to the sealing surface
of the filter stand, then install a new filter cartridge.
4. After the gasket touches the sealing surface of the filter stand,
turn the cartridge about 2/3 turns further.
5. Open levers @ (2 places).
24.7.2 SUPPLY GREASE \ A n

1. When supplying grease to the universal joint, raise the lift arm
and apply the lift arm stay, then stop the engine.

a grease pump.
1. Diagonal brace (2 places)
2. Universal joint (2 places)
3-48
25.7.3 REPLACE OIL IN TRANSMISSION CASE

(INCLUDING TORQUE CONVERTER CASE) AND
CLEAN STRAINER
still hot. Wait until the oil is cooled.
AN143550
0 Container to receive used oil: 47 e (12.2 US gal, 10.3 UK gal)
minimum
0 Replacement oil: 47 !Z (12.2 US gal, 10.3 UK gal) minimum
0 Prepare socket wrenches.
1. Remove undercover @ of the machine body and place a con-

tainer to receive used oil just under the drain plugs @ and 0.
2. Remove drain plugs @ and @ slowly, taking care not to get

soaked with oil, to drain the oil. After draining the oil, tighten the
plugs.
3. Remove bolts @ to remove the strainer of the torque converter

case together with cover 0.
4. Remove pipe @ and bolts 8, then remove the strainer of the

transmission case together with cover 0.
5. If the strainer is broken, replace it with new one.
6. Remove dust from the strainer and wash in light oil. Wash the
inside of the case and plug, etc.
3-49
7. After installing the strainer, supply engine oil through oil filler @
up to the specified level.
8. After supplying the oil, confirm its level according to “24.3

CHECK BEFORE STARTING”.
3-50
24.7.4 REPLACE OIL IN STEERING CLUTCH CASE AND

CLEAN STRAINER
Do not replace the oil

0 Container to receive used oil: 73 a (18.9 US gal, 16.0 UK gal)

minimum
engine.
3. Place a container to receive used oil just under drain plug @ on

the underside of the machine body.
4. Remove drain plug @ slowly, taking care not to get soaked with
oil, to drain the oil. After draining the oil, tighten plug @.
5. Remove cover @ from the left side of the side frame.
6. Remove bolts @to remove cover 0, then take out spring @ and
strainer 0.
7. If the strainer is broken, replace it with a new one.
8. Remove dust from the strainer and wash in light oil. Wash the
inside of the case, spring, and cover, too.
9. After installing the strainer, supply engine oil through oil filler @
up to the specified level.
CHECK BEFORE STARTING”.
11. Set the safety lever of the bucket control lever to FREE position,
then raise the lift arm a little.
horizontally.
3-51
24.7.5 REPLACE OIL IN FINAL DRIVE CASE
a WARNING
Do not replace the oil just after stopping the engine, since it is
0 Container to receive used oil: 23 e (5.9 US gal, 5.0 UK gal)

minimum
1. Place a container to receive used oil just under drain plug 8.
2. Remove drain plug @ to drain the oil. After draining the oil,
tighten plug 8.
3. Supply engine oil through oil filler @ up to the specified level.
For details of the oil to use, see “20. USE OF FUEL, COOLANT 1

EVERY 250 HOURS SERVICE”.
3-52
24.7.6 REPLACE OIL IN HYDRAULIC TANK AND

HYDRAULIC OIL FILTER ELEMENT
Do not replace the oil just after stopping the engine, since it is
Loosen the oil filler cap slowly to release the internal pressure,
0 Container to receive used oil: 63 .f (16.4 US gal, 13.9 UK gal)

minimum
0 Prepare socket wrenches and box wrenches.
1. Lower the bucket to the ground horizontally, and stop the

engine. Move the bucket control lever forward and backward (to
the right and left), then loosen the cap of oil filler @ to release
the internal pressure, then remove it.
r
2. Place a container under drain plug 0 to receive oil.
3. Remove drain plug @to drain oil. After draining oil, tighten plug
0.
When removing drain plug 0, take care not to get soaked with
oil.
L
4. Loosen air breather bolt @ of the hydraulic oil filter, then loosen
drain plug 0.
5. Remove bolt @ to remove cover 0, then remove filter element

0.
6. Wash the removed parts in clean light oil. Wash the inside of the
filter case, too.
7. Install a new filter element and tighten drain plug 0.
8. Supply engine oil through oil filler 0 up to the specified level.

EVERY 250 HOURS SERVICE”.
10. After supplying the oil, loosen air bleeder bolt @ and start the
engine. Let the oil flows out until bubbles do not come out any
more, then tighten air bleeder bolt 0.
11. Wipe off all spilt oil with cloth.
3-53
24.7.7 CHECK OIL FOR UNDERCARRIAGE

Check the oil for the track rollers, carrier rollers, and idler for
consumption according to the following procedure.
1. Park the machine on fiat place.
2. Loosen the seal bolt slowly. If any oil oozes through the threads,
AN143710
the oil is not consumed yet. Tighten the bolt immediately in this
case.
3. If oil does not flow out when the seal bolt is removed, oil is not
sufficient. Ask your Komatsu distributor for repairs in this case.
24.7.8 CHECK CLAMPING PARTS OF TURBOCHARGER

Ask your Komatsu distributor for check of clamping parts of the
turbocharger.
24.7.9 CHECK TURBOCHARGER ROTOR FOR PLAY

Ask your Komatsu distributor for check of the turbocharger rotor
for play.
3-54
Maintenance for every 50, 250, 500 and 1000 hours service
should be carried out at the same time.
24.8.1 SUPPLY GREASE

1. Lower the bucket to the ground horizontally, and stop the
engine.

a grease pump.
I. Steering pedal shaft (IO places)
AN143720
2. Gear shift lever shaft (3 places)
AN143730
3-55
3. Fuel control lever shaft (2 places)
4. Decelerator pedal shaft (3 places)
AN143750
5. Bucket control lever shaft (3 places)
AN143760
3-56
24.82 CLEAN ENGINE BREATHER ELEMENT

1. Remove breather 0.
2. Wash the breather unit in light oil, then dry it by blowing

compressed air against it.
3. Check the inside of the breather hose or pipe for sludge. If any
sludge is sticking, replace the hose or pipe.
4. Replace the O-ring of the breather and apply engine oil to it, then
fit it.
24.8.3 CHECK ALTERNATOR AND STARTING MOTOR

Since the brushes of the alternator and starting motor may be
worn and grease in their bearings may have been used up, ask your
Komatsu distributor for check and repair.
If the engine is started frequently, have them checked every 1000

hours.
24.8.4 CHECK AND ADJUST ENGINE VALVE CLEARANCE

Since special tools are required for check and adjustment of the
engine valve clearance, ask your Komatsu distributor.
25.8.5 CLEAN AND CHECK TURBOCHARGER

Ask your Komatsu distributor to wash and check the turbo-
charger.
25.8.6 CHECK VIBRATION DAMPER

Check the outside of rubber 0 for cracks. If any crack is found,
ask your Komatsu distributor for replacement of the vibration damper.
3-57
Maintenance for every 50,250,500,1000 and 2000 hours service

should be carried out at the same time.
24.9.1 CHECK WATER PUMP

Check the water pump pulley for play. Check water leakage from
the pump and clogging drain hole. If any defect is found, ask your
Komatsu distributor for overhaul or replacement of the water pump.
3-58
SPECIFICATIONS
4-l
25. SPECIFICATIONS
D75S-5
WEIGHT
l Operating weight 21130
(kg)
(Excluding operator) (46592 lb)
PERFORMANCE
l Bucket capacity (m3) 1 2.2
l Maximum load capacity (kg) 1 4,400 (9702 lb)
l Travel speed Forward 1st gear I 0 - 3.3
Forward 2nd gear (km/h) 1 0 - 5.8
Forward 3rd gear (km/h) 1 0 - 9.6
Reverse 1st gear (km/h) 1 0 - 4.3
Reverse 2nd gear (km/h) 1 0 - 7.5
Reverse 3rd gear (km/h) 1 0 - 12.1
l Maximum traction force (N IkgfI) 1 250360 (25530)
l Ground pressure 82.37 (0.84)
ENGINE
l Model Komatsu S6D125E-2 diesel engine
l Rated output 151.51 kW 1206 PSI/2000 rpm
l Maximum torque 922 N.m I94 kgf.m1/1500 rpm
0 Starting motor 24 V 7.5 kW
l Alternator 24 V 35 A
l Battery 12 V 170 Ah x 2 pieces
4-2
D75S-5
/”
,’
/’
---_-
AD21 5288
4-3
25. SPECIFICATIONS
D75-5 (with cab (option))
(,Z
(,9 ,o I)
(,E ,EI) 9SOP
,81)9P95
OOZE II-’
I
(,L ‘L) E6 1
’ (,Z ‘4 I) 08c
AD21 5278
4-4
OPTIONS, ATTACHMENTS
5-1
26. INSTALLATION OF FIRE EXTINGUISHER
A fire extinguisher can be installed to the oosition shown below.
AD215130
l For the parts necessary for installation of a fire extinguisher, ask your Komatsu distributor.
5-2
27. HANDLING WITH CABIN INSTALLED
27.1 HOW TO READ LAMPS AND USE SWITCHES
AM143790
1. Ktwn wlrtn avwibn

Used to operate the rear windshield wiper.
ON Position: The windshield wiper starts.
Turning to right: The window washer switch is turned on to spout
washing fluid.
AD14380B
2. FRONT WIPER SWITCH

Used to operate the front windshield wiper.
ON Position: The windshield wiper starts.
Turning to right: The window washer switch is turned on to spout
washing fluid.
hD14380B
3. FRONT WORKING LAMP SWITCH

Used to turn on and off the working lamp at the front of the
cabin.
ON position: The lamp is turned on.
I AD143828
5-3
4. REAR WORKING LAMP SWITCH

Used to turn on and off the working lamp at the rear of the cabin.
ON
OFF
AD143828
5. PILOT LAMP OF FRONT WORKING LAMP

Lights up when the front working lamp is turned on.
AM143840
6. PILOT LAMP OF REAR WORKING LAMP

Lights up when the rear working lamp is turned on.
An143840
7. ROOM LAMP SWITCH

Used to turn on and off the room lamp
ON
OFF
8. CIGARETTE LIGHTER
Used to light cigarettes.
If this lighter is pushed in, it returns in several seconds. Pull it
out to light a cigarette.
0
9
AM143870
5-4
27.2 FUSE BOX
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from

burning out.
If the fuse becomes corroded or white powder can be seen, or
the fuse is loose in the fuse holder, replace the fuse.
Replace a fuse with another of the same capacity.
Remove bolt 0, and remove cover 0.
L
I3 An143880
Fuse capacity and circuit Iname

Terminal 1 Fuse
No. Circuit name 3emarks
symbol capacity
Front windshield wiper El
I
L 20A
Rear windshield wiper
Front working lamp 0
Pilot lamp of front working lamp

H IOA Rear working lamp AM143890
Pilot lamp of rear working lamp
Room lamp
0 F 10A Cigarette lighter
0 0
5-5
27.3 DOOR LOCK I
Used to lock the door open.
1. Push lever @ above catcher 0 of the upper door, and the catcher
is released and the upper and lower parts of the door can be
separated.
2. If the upper door is pressed against catcher 0, it is fixed.
3. If lever @I under the catcher is pressed, the catcher is released

and the door can be opened.
When fixing the door, fix it to the catcher securely.
27.4 WHEN REQUIRED
Check the fluid level in washer fluid tank 0. If it is not sufficient,

add window washing fluid for automobiles.
NOTICE
When adding the washing fluid, take care that dust will not
enter the eyes.
5-6
27.5 PRECAUTIONS FOR WORK

27.5.1 INHIBITION OF KEEPING DOOR OPEN DURING
OPERATION (MACHINE WITH CAB)
When driving and operating the machine, keep the doors closed.
If the doors are not closed, they may be broken by strong vibration
and obstacles.
27.5.2 INHIBITION OF MODIFICATION OF CAB GLASSES

TO WORSEN VISIBILITY (MACHINE WITH CAB)
o Installation of anything which can worsen the visibility to the cab
glasses is inhibited by the law.
o Do not anything which can worsen the visibility to the glasses.
o Keep the glasses clean and always work safely.
27.5.3 PRECAUTIONS ON BLIND SPOTS BEHIND CAB

PILLARS
Some blind spots are made by the cab pillars
cles or workers around the machine.
5-7
28. OPERATION OF AIRCONDITIONER
28.1 NAME OF EACH PART OF CONTROL PANEL

ZONTROL PANEL
1. AIR OUTLET CHANGEOVER KNOB
Knob position Air outlet Uses
I
FACE Overhead outlet Cooling, ventilation
Intermediate position Foot area outlet Heating, cooling (Air flow
between FACE and Overhead outlet rate frin eacg iytket cab be
FOOT Defroster outlet adjusted for each knob
position
FOOT Foot area outlet
Heating, drying/heating
DEF Defroster outlet i
2. FRESH/RECIRC CHANGEOVER KNOB

UR OUTLET
Used to change the air intake openings for cooling and heating.
0 Recirc air .... .... ....... Air in the cab is taken in (Usually used for
cooling).
0 Recirc + Fresh ...... Fresh air is taken in, as well as air in the cab
(Usually used for heating, ventilation and
pressurizing).
3. HEATER TEMPERATURE CHANGEOVER KNOB

Used to control the temperature in the heating mode.
0 As the knob is moved toward “HIGH HEAT”, the air temperature

at the air outlet is heightened.
0 If the knob is set to “OFF” position, the water valve is closed and
the heating function is turned off.
4. COOLER TEMPERATURE CHANGEOVER KNOB

Used to control the temperature in the cooling mode. Used as
the cooler switch, too.
0 As the knob is moved toward “HIGH COOL”, the air temperature

at the air outlet is lowered.
0 If the knob is set to “OFF” position, the cooler switch is turned
off and the heating function is turned off.
5. BLOWER SWITCH
Used to adjust the air flow rate in the cooling and heating modes,
and used as the main switch.
l The air flow rate can be set to three levels of “LOW”, “MED” and
“HIGH”.
l If this switch is turned “OFF”, the power is turned off and the air-
conditioning function is turned off.
5-8
28.2 OPERATION METHOD

COOLING MODE
If the control knobs are set as shown in the figure, comfortable
cool air blows from the overhead air outlet.
l Set knobs @ - @ as shown in the figure.

l Set knobs @ and @ as shown below, according to your prefer-
ence.
@ Cooling temperature o Blower switch
VENTILATION COOLING MODE

If the air in the cab becomes dirty, set the control knobs as
follows to ventilate and cool the cab.
l Set knobs @) - @ as shown in the figure.

ence, similarly to the ordinary cooling mode.
l If the ventilation cooling is continued for a long time, the cooling

effect may become insufficient. After ventilation is finished,
return Fresh/Recirc changeover knob @ to the “Fresh position
5-9
HEATING MODE
If the control knobs of the control panel and that at the right of
the ceiling of the cab are set as shown below, hot air blows from the
foot area air outlet and defroster outlet.
l Set knobs 0, @ and @ as shown in the figure.

l Set knobs @I and @ as shown below, according to your prefer-
ence.
@ ~~~~r~, tintrrat”re @ Blower switch
Quick heating HIGH HEAT HIGH

Ordinary heating MED HEAT MED - LOW
Low heating LOW HEAT LOW
RECIRCULATION HEATING MODE

If the outside air is dirty with dust, smells bad, etc., set the
control knobs as shown in the figure to recirculate the air.
l Set knobs CTJ,@ and @ as shown in the figure.

ence, similarly to the ordinary heating mode.
l If the recirculation heating is continued for a long time, the air

in the cab becomes dirty. Accordingly, return Fresh/Recirc
changeover knob @ to the “Fresh + Recir position (&I” for

operation in the normal environment.
5-10
DRYING HEATING MODE

If the control knobs of the control panel are set as shown in the
figure, hot dry air blows from the foot area air outlet and defroster
outlet.
l Set knobs 0, @ and @ as shown in the figure.

ence.
@ Heater temperature
@ Blower switch
control knob
Drying heating in winter HIGH HEAT HIGH
Drying heating in spring
MED HEAT MED - LOW
and autumn
l If this mode is used when the air in the cab in spring, autumn
or on a rainy day, the cab is heated comfortably without fogging
the window glasses.
l If the outside temperature is 2 - 6.5% or below, the compressor

is automatically turned off and drying heating mode cannot be
used.
VENTILATION MODE
If the control knobs are set as shown in the figure, fresh air flow
out of the overhead outlet to ventilate the cab.
l Set knobs @ - @ as shown in the figure.

l Set blower switch @to “LOW”, “MED” or “HIGH” according to
your preference.
5-11
WHEN AIRCONDITIONER IS NOT USED

While the airconditioner is not used, set the control knobs as
shown in the figure.
d d b AD215266
28.3 PRECAUTIONS FOR USE OF

AIRCONDITIONER
l After parking the machine in a place where it receives the direct

sunlight
If the machine is parked in a place where it receives direct
sunlight for a long hours, the temperature in the cab become very
high. In this case, open the windows fully to let the hot air out, then
operate the airconditioner.
After the cab is cooled, close the windows and set the tempera-
ture to a desired level.
l When eyes feel drying

If you smoke in an cooled cab, your eyes may feel dry. In this
case, open the windows to let the smoke out.
0 Proper cooling operation

The airconditioner makes a comfortable air by lowering tem-
perature and humidity. It is good for health to set the temperature
to the degree you feel a little cool when you rides in the machine
(when temperature difference between the outside and inside is 5 -
6°C). If the cab is too cool, your health may be affected. Take care
in adjusting the temperature.
l When the window glasses become foggy

The glasses become foggy easily and the visibility is lowered on
a rainy day. In this case, operate the cooler, and the glasses are
cleared up.
5-12
28.4 INSPECTION AND MAINTENANCE

CHECK OF COMPRESSOR BELT TENSION Approx 1Omm (0. 4in)
If the belt is loosened, it slips and the cooling effect is lowered.
Check the belt tension occasionally by pressing its center between
the drive pulley and compressor pulley, and adjust the tension so
that the belt will be deflected by about IO mm (0.4 in) when it is
pressed with the force of about 58.8 N 16 kgf, 13.2 Ibft}.
AEl62378
If the belt is new, it is lengthened remarkably. Accordingly, be
sure to adjust its tension in two - three days.
CHECK OF QUANTITY OF REFRIGERANT
refrigerant gets in the eyes or on the hands, you may be blinded

or receive frostbite, Never loosen the refrigerant parts!
If the refrigerant is insufficient, the cooling effect is lowered.

While the engine and the airconditioner are running at the full speed,
check the flowing condition of the refrigerant in the sight glass
(inspection window) of the receiver.
l No bubbles are contained in the flow ...... ............. ........... Proper

l Some bubbles are contained
(and pass continuously) in the flow .... ...... ............. ... Insufficient
l Colorless and transparent .......... ............ ...... ...... ... No refrigerant b
REMARK
If bubbles are seen, the refrigerant is insufficient. In this case,
have a distributor add the refrigerant. If the airconditioner is oper-
ated with insufficient refrigerant, the compressor may be broken. If
leakage of refrigerant is left, the inside of the airconditioner will be
rusted.
CHECK OUT OF SEASONS

Operate the airconditioner even out of the season for 3 - 5
minutes once in a month to keep the compressor parts lubricated.
5-13
28. OPERATION OF AlRCONDlTlONER
INSPECTION AND MAINTENANCE LIST OF AIRCONDITIONER
Inspection and Contents of inspection

Maintenance period
maintenance item and maintenance
Refrigerant Charged quantity In spring and autumn
(Twice a vear)
Condenser Clogging of fins WHEN REQUIRED
Comoressor
-----r- ----
Ooeratina condition 4000 HOURS SERVICE
V-belt Damage and tension 250 HOURS SERVICE
Blower motor Operating condition WHEN REQUIRED
Control mechanism Ooeratina condition WHEN REQUIRED
Mounting condition,
looseness of clamps
Piping WHEN REQUIRED
and joints, gas leakage,
damage
2 - 4-season mainte-
Receiver, drier Replacement
nance
5-14
29. GENERAL PRECAUTIONS
29.1 SAFETY PRECAUTIONS

If an attachment, option, etc. other than the ones approved by Komatsu is installed, the life of the
machine is shortened and safety may be lowered.
When installing an attachment not described in this manual, consult your Komatsu distributor. If we
are not notified, we can not take any responsibility.
A WARNING
Precautions for removal and installation
When removing or installing an attachment, observe the following precautions and work safely.
When removing or installing an attachment, work on a flat and level place.
When two or more workers work together, signs must be made and they must work according
to those signs.
When carrying a heavy item (25 kg or heavier), use a crane.
When removing a heavy item, be sure to prepare a support in advance. When hanging it with
a crane, take care of the location of the center of gravity.
It is dangerous to work on an item hung with a crane. be sure to support on a stand and confirm
safety.
When leaving a removed attachment or installing it, place it stably so that it will not fall down.
Do not stand under an items hung with a crane. Keep aside so that you will be safe even if that
item falls.
NOTICE
A qualification or license is required to operate a crane. A person not qualified must not operate
the crane.
For details of removal and installation of the attachments, consult your Komatsu distributor.
5-15

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EMISSION CONTROL WARRANTY

EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)

KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

GARANTIE SUR LE CONTR~LE DES EMISSIONS

~NONCG DE GARANTIE SUR LE CONTR~LE DES OMISSIONS (APPLICABLE AU CANADA SEULEMENT):

KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSkQUENTS.

CEHQ000700 - Komatsu America International Company 12199

. ENGINE FAMILY DISPLACEMENT LITERS -

VALVE LASH IN. EX. FUEL RATE mm3/STROKE-

IDLE SPEED RPM FAMILY EMISSION LIMIT

RkGLAGE DE UALLUMAGE - KOMATSU LTD.

ENGINE DATAPLATE - ENGLISH / FRENCH

A WARNING - This word is used on safety messages

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

3.1 INTENDED USE

3.3 BREAKING IN THE MACHINE

4.1 MACHINE SERIAL NO. PLATE POSITION

4.2 ENGINE SERIAL NO. PLATE POSITION

4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.:

Engine serial No.:

Service personnel for your machine:

2. Safety information ............................................................................................................................ o- 2

4. Location of plates, table to enter serial No. and distributor ...................................................... 0- 4

7. Precautions during operation .......................................................................................................... I- 7

6. Precautions for maintenance ........................................................................................................... 1-19

9. Position for attaching safety labels ................................................................................................ l-28

10. General view ...................................................................................................................................... 2- 2

11. Explanation of components ............................................................................................................. 2- 4

14. weather operation .................................................................................................................... 2-60

15. Long-term storage ............................................................................................................................. 2-63

16. Troubleshooting ................................................................................................................................. 2-64

18. Outlines of service ............................................................................................................................ 3- 4

19. Wear parts list ................................................................................................................................... 3- 7

24. Service Procedure .............................................................................................................................. 3-18

27. Handling with cabin installed ........................................................................................................... 5- 3

28. Operation of airconditioner.. ............................................................................................................. 5- 8

29. General precautions ........................................................................................................................... 5-15

result in serious injury or death.

This safety section also contains precautions for optional equip-

1 CLOTHING AND PERSONAL PROTECTIVE ITEMS 1

--j UNAUTHORIZED MODIFICATION 1

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT

FIRE PREVENTION FOR FUEL AND OIL

A0055020 A0055030 A0055040

Asbestos dust can be hazardous to your health if it is inhaled.

1 CRUSHING OR CUTTING PREVENTION 1

FIRE EXTINGUISHER AND FIRST AID KIT

PRECAUTIONS FOR AlTACHMENTS

PRECAUTIONS WITH SEAT BELT

7.1 BEFORE STARTING ENGINE

CHECKS BEFORE STARTING ENGINE

- PRECAUTIONS FOR LOCKING WINDOW GLASS AT MAINTENANCE

PRECAUTIONS FOR USE OF MIRRORS (OPTIONAL), WINDOW GLASS

7.2 AFTER STARTING ENGINE

CHECKS AFTER STARTING ENGINE

PRECAUTIONS WHEN STARTING OFF

4 CHECK WHEN CHANGING DIRECTION 1

PRECAUTIONS WHEN TRAVELING

-j’ SECURING ENOUGH VISIBILITY 1

OPERATE CAREFULLY ON SNOW

Always close the door of the operator’s compartment.

4 PRECAUTIONS IN COLD AREAS 1