Eenam03355 D65ex PX WX-18 1806

Operation & EENAM03355
Maintenance Manual
D65EX-18
D65PX-18
D65WX-18
BULLDOZER
SERIAL NUMBER
D65EX-18 - 90001 and up
D65PX-18 - 90001 and up
D65WX-18 - 90001 and up
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read ORIGINAL INSTRUCTIONS
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
FOREWORD
Komatsu recommends that any service parts used for maintenance, repair or
replacement of emission control systems be genuine new Komatsu or Ko-
matsu approved rebuilt parts or assemblies or others parts of equivalent
quality, and that the engine be serviced by an authorized Komatsu distribu-
tor. Failure to follow these recommendations could result in ineffective serv-
ice, damage to the product or safety risks (including personal injury or
death).
1-1
READ THIS MANUAL FOREWORD
READ THIS MANUAL

This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the indicated location so that all relevant personnel can
read it at any time.
Operation and Maintenance Manual Storing Place:
It is provided on the back side of the operator's seat back.
If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine
model name and the serial No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to
arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and
the serial No.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. If there is any question or suggestion, consult your Ko-
matsu distributor.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
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, 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 your Komatsu distributor before
operating the machine.
1-2
FOREWORD KOMATSU MACHINE OPERATOR PRIVACY POLICY
KOMATSU MACHINE OPERATOR PRIVACY POLICY

This Privacy Policy governs the processing of personal data which takes place when operators based in the Eu-
ropean Economic Area or EEA (which consists of the EU, Norway, Liechtenstein or Iceland) operate Komatsu
machines equipped with Machine Monitoring Systems such as KOMTRAX, KOMTRAX Plus, K-plus 2, iMC or
Smart Construction Cloud system (hereinafter together referred to as "Machine Monitoring Systems" or "MMS"),
i.e. systems that allow the wireless monitoring of Komatsu machines.
The MMS are globally managed and maintained by Komatsu Limited, a Japanese corporation having its princi-
pal place of business at no. 3-6, Akasaka 2-Chome, Minato-Ku, Tokyo, Japan ("Komatsu"). MMS are made
available in the EEA by Komatsu Europe International NV, a corporation organised and existing under the laws
of Belgium, with registered office at 1800 Vilvoorde, Belgium, Mechelsesteenweg 586, registered in Brussels un-
der number RPR/CER(0)404.968.268 ("Komatsu Europe", together with the other Komatsu subsidiaries in the
EEA referred to as "we" or "us"). Komatsu Europe acts as Komatsu's representative in the EU with respect to
MMS.
1. Who is responsible?
Komatsu, Komatsu Europe, Komatsu distributors and dealers, as well as the owner of the machine and your
employer (when your employer is not the owner) are all responsible for the processing of your personal data
through MMS.
2. How are responsibilities allocated?
To arrange for the aforementioned shared responsibility, Komatsu, Komatsu Europe, the distributors, dealers,
owners and your employer have put in place contractual arrangements between them which govern this shared
responsibility.
The essence of these arrangements is that you can always direct your questions and requests regarding
the processing of your personal data (i.e. storage, collection, transfer etc. of all information that relates to you as
operator) to the party with whom you have most direct relationship.
In principle this means that you should first and foremost refer to your employer (if you are an employee) or
your customer (if you are an independent contractor). Komatsu, Komatsu Europe, Komatsu distributors and
dealers, as well as the owner of the machine and your employer/customer (if he is not the owner) will liaise be-
tween each other to ensure that your questions, requests and rights regarding the processing of your personal
data are given due regard.
To be clear:
• For staff members of Komatsu Europe or of other Komatsu subsidiaries in the EEA, the request can be di-
rected directly to Komatsu Europe by sending an e-mail to PrivacyOffice@komatsu.eu
• For staff members or independent contractors of a distributor, a dealer or an owner, meaning you either
work for or on behalf of a distributor, a dealer or an owner, you are to contact the distributor, the dealer or
the owner with your questions or requests.
• For staff members or independent contractors of another entity than the ones referred to above, you are to
contact first and foremost your employer or customer.
If you are unsure who to contact, please send an e-mail to Komatsu Europe at PrivacyOffice@komatsu.eu stat-
ing your full name, function title and entity you work for, and we will refer your request to the appropriate respon-
sible party.
3. What sort of personal data is processed?
When you use a machine equipped with MMS, the following types of personal data are collected and process-
ed:
• personal identification data (e.g. names)
• current employment (e.g. function title and employer details)
• details regarding:
• your use and operation of the machine
• machine location and position
• usage times and statistics
• error codes and frequency of those codes
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KOMATSU MACHINE OPERATOR PRIVACY POLICY FOREWORD
• pictures, videos and sound recordings

4. Why is your personal data processed?
When you use Komatsu machines equipped with MMS, your personal data are processed for the following rea-
sons:
(a) Safety and security
(b) Warranty
(c) Misuse and theft prevention
(d) To provide training and develop training materials
(e) To improve machine and operational efficiency
(f) To improve jobsite safety and efficiency
(g) To provide faster and more tailored support service
(h) To optimize jobsite layout, machine resource allocation and driving routes
(i) For real-time jobsite monitoring and management
(j) Where applicable: to follow-up on rental agreements
(k) To improve MMS and associated services
(l) To evaluate, analyse and report on machine usage
(m) To comply with a legitimate request from law enforcement or other authorities
We may also process your personal data to inform a third party in the context of a possible merger with, acquisi-
tion from/by or demerger by that third party, even if that third party is located outside of the EU.
Please note that your employer can also use MMS to process data to evaluate your performance as employee
as well as for other purposes, but this is entirely between you and your employer.
5. What makes the processing of your personal data legitimate?
The data protection laws require us to precisely indicate to you which legal option we rely on to make the proc-
essing of your personal data legitimate. We need to clarify this for each of the purposes listed in section 4
above.
For the purposes (a) to (l) as indicated in section 4 above as well as for the purpose of informing a third party in
the context of a possible merger, acquisition or demerger, the processing of your personal data is necessary for
our legitimate interests, which in this case concern:
• ensuring the safe and secure deployment of the machines
• preventing misuse and theft
• commercial interests which include handling warranties, the need to be able to improve MMS, our ma-
chines and services and training materials and the need to be able to enter into corporate transactions.
For purpose (m) we need to process your personal data to comply with our legal obligations.
6. Recipients and transfers
Your personal data may be sent to the following categories of recipients:
• yourself
• your employer or business relations
• companies within the Komatsu group of companies, including our affiliates, as well as our service providers
who help us to provide MMS
• governmental, judicial and other competent bodies in case of a justified yet legally binding request
Your personal data are transferred to Japan, for which model contract clauses on the basis of European Com-
mission decision 2004/915/EC have been put in place between Komatsu and Komatsu Europe.
For more information, please address your questions to PrivacyOffice@komatsu.eu
7. How long will your personal data be stored?
Your personal data are only processed for as long as needed to achieve the purposes listed in section 4 above.
We will de-identify your personal data when they are no longer necessary for the purposes outlined in the pur-
pose for processing, unless there is:
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FOREWORD KOMATSU MACHINE OPERATOR PRIVACY POLICY
• an overriding interest of Komatsu, Komatsu Europe or any third party in keeping your personal data identifi-
able
• a legal or regulatory obligation or a judicial or administrative order that prevents us from de-identifying them
8. Which rights do you have with regard to the processing of your personal data?
You have the right to request access to all personal data processed in MMS insofar it pertains to you. You can
exercise this right first and foremost via most MMS directly. We reserve the right to refuse multiple requests for
access that are clearly submitted for causing nuisance or harm to Komatsu, Komatsu Europe or other parties.
You have the right to ask that any personal data pertaining to you which are inaccurate, are corrected free of
charge. Some personal data you can correct yourself if you have access to the MMS web portal. If a request for
correction is submitted, such request must be accompanied of proof of the flawed nature of the data for which
correction is asked.
You have the right to request that personal data pertaining to you will be deleted if they are no longer required in
light of the purposes outlined above. However, you need to keep in mind that a request for deletion will be eval-
uated by us against:
• overriding interests of Komatsu, Komatsu Europe or any other third party
• legal or regulatory obligations or administrative or judicial orders which may contradict such deletion
Instead of deletion you can also ask that we limit the processing of your personal data if and when (a) you con-
test the accuracy of that data, (b) the processing is illegitimate or (c) the data are no longer needed for the pur-
poses which are outlined above, but you need them to defend yourself in judicial proceedings.
You have the right to oppose the processing of personal data for the purposes (a) to (l) in section 4, but you are
required to explain your particular circumstances on which your request for opposition is based.
As explained earlier, if you wish to submit a request to exercise one or more of the rights listed in this section,
you must first and foremost contact your employer. Each request addressed to us can be sent via e-mail to
PrivacyOffice@komatsu.eu for all data subject right matters.
An e-mail requesting to exercise a right will not be construed as consent with the processing of your personal
data beyond what is required for handling your request. Such request should clearly state and specify which
right you wish to exercise and the reasons for it, if such is required. It should also be dated and signed, and
accompanied by a digitally scanned copy of your valid identity card proving your identity.
Without prejudice to the allocation of responsibilities as outlined in section 1, we will promptly inform you of hav-
ing received this request. If the request proves valid, we will notify you as soon as reasonably possible and at
the latest thirty (30) days after having received the request.
If you have any complaint regarding the processing of your personal data by Komatsu or Komatsu Europe via
MMS, you may always contact us via the e-mail address mentioned in the first paragraph of this clause. If you
remain unsatisfied with our response, you may file a complaint with the competent data protection authority.
1-5
SAFETY INFORMATION FOREWORD
SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
This signal word indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices that may
cause property damage.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
If precautions described are not observed, the machine may be damaged or the service life
may be reduced.
This word is used for information that is useful to know.
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FOREWORD NOISE
NOISE
Two labels indicating the machine noise level are affixed on the machine.
• Sound pressure level at the operator’s station, measured
according to ISO 6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the meas-
ured time-averaged A-weighted emission sound pressure
level at the operator’s position is 2.5dB, in accordance with
ISO 11201
• Sound power level emitted by the machine, measured ac-

cording to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
This value includes an uncertainty of 1.5 dB.
1-7
VIBRATION LEVELS FOREWORD
VIBRATION LEVELS
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper-
ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with
ISO 7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this
value is 0.94 m/s2 according to EN12096:1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is 0.29
m/s2 according to EN12096:1997.
These values were determined using a representative machine and measured during the typical operating con-
dition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1
and ISO 5349.
VIBRATION - OPERATING CONDITION

TRACTOR DOZER (Dozing and spreading material through forward/reversing motion)
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE

The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
• Tire pressures (for wheeled machines), tension of crawler (for crawler machines)
• Brake and steering systems
• Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and travelling in good condition
• Remove any large rocks or obstacles
• Fill any ditches and holes
• Site manager should provide machine operators with machine and schedule time to maintain terrain
conditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
• Adjust the seat and suspension for the weight and size of the operator
• Wear seat belt
• Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
• When pushing with bucket or blade, avoid sudden loading; load gradually
• Drive around obstacles and rough terrain conditions
• Slow down when it is necessary to go over rough terrain
• Make the curve radius of travelling path as large as possible
• Travel at low speed when travelling around sharp curves
7. Minimize vibrations for long work cycle or long distance travelling
• Reduce speed to prevent bounce
• Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
• Operate the machine only when you are in good health
• Provide breaks to reduce long periods of sitting in the same posture
• Do not jump down from the cab or machine
1-8
FOREWORD VIBRATION LEVELS
• Do not repeatedly handle and lift loads
1-9
INTRODUCTION FOREWORD
INTRODUCTION
MAIN USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
• Dozing work
• Leveling work
• Cutting into hard or frozen ground or ditching
• Works of felling trees and removing stumps
For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS”.
DIRECTIONS OF MACHINE
In this Operation and Maintenance Manual, the directions of the machine (front, rear, right, left) are determined
according to the view from operator's seat (E) in the direction of travel (front) of the machine.
(A) Front (D) Right
(B) Rear (E) Operator's seat
(C) Left (F) Sprocket
VISIBILITY FROM OPERATOR'S SEAT

This machine complies with the visibility standard (ISO 5006).
1-10
FOREWORD INTRODUCTION
This machine maintains a proximity visibility of a height of 1.5 m and 1.2 m at a point 1 m away from the outside
surface of the machine, and a visibility for a radius of 24 m.
Height to evaluate the proximity visibility

Region of the RB
Machine type Mass
Front side Left-hand side Right-hand side Rear side
Dozer m >18 t 1.5 m 1.5 m 1.5 m 1.2 m
1-11
INTRODUCTION FOREWORD
To assist with job site organisation during use of this machine, a visibility map is provided that shows an approxi-
mation of any masking to visibility between the 1 m rectangular boundary and the 24 m test circle.
Based upon the information supplied in the visibility map the site operator may wish to provide additional meas-
ures where it is felt necessary or provide additional instruction to personnel.
Specification of visibility map
• Machine Posture : In accordance with ISO5006
• Evaluation height : 1.2 m above the ground
• Scale-interval of the circles is 1 m.
1-12
FOREWORD ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS

EMISSION
About Engine Technology

This engine technology combines a Komatsu Diesel Particulate Filter (KDPF) and Komatsu’s Urea Selective
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union.
• Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the
exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process
to burn the soot is performed automatically to keep the filtering performance of KDPF high.
• Komatsu’s Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the
exhaust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust
gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and
decomposes the nitrogen oxides into nitrogen and water.
About Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid is the reagent for the SCR system.
DEF is the abbreviation for Diesel Exhaust Fluid, and is represented as DEF throughout this manual.
DEF is a colorless transparent and aqueous urea solution made with 32.5 % urea (AUS32) and 67.5 % deion-
ized water. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical
products, and fertilizer, etc.
Commercial DEF, commonly referred to as AdBlue® in the European Union, that quality standards are main-
tained in accordance with DIN70070 and ISO 22241-1, to be used.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
1-13
PRODUCT INFORMATION FOREWORD
PRODUCT INFORMATION
When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items.
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-

AL NO. PLATE
This is at the bottom left at the front of the operator's seat.
The design of the nameplate differs according to the district.
LOCATION OF ENGINE NUMBER PLATE

This is located on top of the engine head cover on the right side of the machine.
FLUORINATED GREENHOUSE GASES

Product contains fluorinated greenhouse gases.
1-14
FOREWORD PRODUCT INFORMATION
Standard spec.
Wide air condensor spec.

Product contains
fluorinated
greenhouse gases
1.1 kg
HFC-134a
CO2 eq. 1.57 t
GWP 1430
09971-10111
SERVICE METER LOCATION

This is displayed on the machine monitor.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Machine serial No.
Engine serial No.
Product identification number
(PIN)
Manufacturers name: KOMATSU LTD.
Address: 2-3-6 Akasaka
Minato-ku, Tokyo 107-8414
Japan
Authorised representative: KOMATSU EUROPE INT.
Address: Mechelsesteenweg 586
B-1800 Vilvoorde
Belgium
Distributor name
Address
Service personnel
1-15
PRODUCT INFORMATION FOREWORD
Phone/Fax
1-16
FOREWORD SERIAL PLATE
SERIAL PLATE
B C
D E
F
EI000001
A MACHINE DESIGNATION/TYPE E ENGINE POWER
B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER
C YEAR OF CONSTRUCTION G MANUFACTURER
D OPERATING MASS H AUTHORISED REPRESENTATIVE
1-17
DECLARATION OF CONFORMITY FOREWORD
DECLARATION OF CONFORMITY
The manufacturer/Authorised representative
The manufacturer Authorised representative
KOMATSU LTD. KOMATSU EUROPE INT.
2-3-6 Akasaka Mechelsesteenweg 586
Minato-ku, Tokyo 107-8414 B-1800 Vilvoorde
Japan Belgium
Declares that this machine:

D65EX-18
D65PX-18
D65WX-18
Fulfils all the relevant provisions of following EC Directives:
Machinery Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2014/30/EU
Outdoor Noise Directive 2000/14/EC amended by 2005/88/EC
Radio Equipment Directive 2014/53/EU
1-18
FOREWORD TABLE OF CONTENTS
TABLE OF CONTENTS
FOREWORD.................................................................................................................................................... 1-1
READ THIS MANUAL ............................................................................................................................... 1-2
KOMATSU MACHINE OPERATOR PRIVACY POLICY ............................................................................ 1-3
SAFETY INFORMATION .......................................................................................................................... 1-6
NOISE....................................................................................................................................................... 1-7
VIBRATION LEVELS ................................................................................................................................ 1-8
VIBRATION - OPERATING CONDITION ........................................................................................... 1-8
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ................................................................ 1-8
INTRODUCTION .................................................................................................................................... 1-10
MAIN USE OF MACHINE ................................................................................................................ 1-10
DIRECTIONS OF MACHINE............................................................................................................ 1-10
VISIBILITY FROM OPERATOR'S SEAT .......................................................................................... 1-10
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION ................................................... 1-13
PRODUCT INFORMATION..................................................................................................................... 1-14
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ...... 1-14
LOCATION OF ENGINE NUMBER PLATE ...................................................................................... 1-14
FLUORINATED GREENHOUSE GASES......................................................................................... 1-14
SERVICE METER LOCATION ......................................................................................................... 1-15
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR............................................................ 1-15
SERIAL PLATE ....................................................................................................................................... 1-17
DECLARATION OF CONFORMITY ........................................................................................................ 1-18
SAFETY........................................................................................................................................................... 2-1
SAFETY.................................................................................................................................................... 2-2
SAFETY LABELS ..................................................................................................................................... 2-4
LOCATION OF SAFETY LABELS...................................................................................................... 2-5
CONTENTS OF SAFETY LABELS .................................................................................................... 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-10
PRECAUTIONS BEFORE STARTING OPERATION........................................................................ 2-10
PREPARATIONS FOR SAFE OPERATION ..................................................................................... 2-10
PRECAUTIONS TO PREVENT FIRE................................................................................................2-11
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................. 2-13
DO NOT GET CAUGHT IN WORK EQUIPMENT ............................................................................ 2-15
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................................ 2-15
UNAUTHORIZED MODIFICATION .................................................................................................. 2-16
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................... 2-16
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ..................................................... 2-16
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-17
PRECAUTIONS FOR JOBSITE ....................................................................................................... 2-17
START ENGINE............................................................................................................................... 2-19
PRECAUTIONS FOR OPERATION ................................................................................................. 2-21
PRECAUTIONS FOR TRANSPORTATION...................................................................................... 2-24
TOWING AND BEING TOWED........................................................................................................ 2-25
PRECAUTIONS FOR MAINTENANCE ................................................................................................... 2-26
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-26
PRECAUTIONS FOR CHECK AND MAINTENANCE ...................................................................... 2-30
PRECAUTIONS FOR DEF...................................................................................................................... 2-36
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING .................................................. 2-36
PRECAUTIONS FOR ADDING ........................................................................................................ 2-36
PRECAUTIONS FOR STORING...................................................................................................... 2-36
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE .................................................................... 2-36
OTHER PRECAUTIONS.................................................................................................................. 2-36
OPERATION .................................................................................................................................................... 3-1
GENERAL VIEW....................................................................................................................................... 3-2
MACHINE EQUIPMENT NAME ......................................................................................................... 3-2
CONTROLS AND GAUGES NAMES ................................................................................................. 3-4
EXPLANATION OF COMPONENTS ......................................................................................................... 3-6
1-19
TABLE OF CONTENTS FOREWORD
EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................... 3-6

SWITCHES ...................................................................................................................................... 3-81
CONTROL LEVERS AND PEDALS ................................................................................................. 3-87
OTHER EQUIPMENT ...................................................................................................................... 3-96
MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-132
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-132
METHOD FOR STARTING ENGINE.............................................................................................. 3-159
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-164
METHOD FOR STOPPING ENGINE ............................................................................................. 3-167
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MA-
CHINE ........................................................................................................................................ 3-169
SHIFT GEARS ............................................................................................................................... 3-171
METHOD FOR SWITCHING BETWEEN FORWARD AND REVERSE .......................................... 3-176
METHOD FOR STEERING MACHINE........................................................................................... 3-177
RECOMMENDED WORKING MODES FOR WORKS ................................................................... 3-179
PRECAUTIONS FOR OPERATION ............................................................................................... 3-181
PRECAUTIONS WHEN OPERATING ON SLOPE......................................................................... 3-182
PRECAUTIONS FOR USING BRAKE ........................................................................................... 3-183
DO NOT OPEN DOOR WHILE OPERATING MACHINE ............................................................... 3-183
DO NOT MODIFY CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW ...................... 3-183
PRECAUTIONS FOR FLOATING OPERATION............................................................................. 3-183
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES .................. 3-184
RECOMMENDED APPLICATIONS................................................................................................ 3-184
METHOD FOR ADJUSTING WORK EQUIPMENT ........................................................................ 3-185
TIPS FOR LONGER UNDERCARRIAGE LIFE .............................................................................. 3-192
METHOD FOR PARKING MACHINE ............................................................................................. 3-195
METHOD FOR CHECKING AFTER FINISHING WORK ................................................................ 3-197
LOCK ............................................................................................................................................. 3-197
HANDLE AIR CONDITIONER............................................................................................................... 3-202
EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-203
METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-207
HANDLING RADIO ............................................................................................................................... 3-216
EXPLANATION OF RADIO EQUIPMENT ...................................................................................... 3-216
METHOD FOR CONTROLLING RADIO ........................................................................................ 3-218
ANTENNA...................................................................................................................................... 3-220
TRANSPORTATION.............................................................................................................................. 3-221
TRAVEL ON ROAD........................................................................................................................ 3-221
PRECAUTIONS FOR TRANSPORTING MACHINE ...................................................................... 3-221
TRANSPORTATION PROCEDURE ............................................................................................... 3-221
METHOD FOR REMOVING WORK EQUIPMENT......................................................................... 3-221
LOADING AND UNLOADING WITH TRAILER .............................................................................. 3-222
METHOD FOR LIFTING MACHINE ............................................................................................... 3-226
COLD WEATHER OPERATION............................................................................................................ 3-229
COLD WEATHER OPERATION INFORMATION ........................................................................... 3-229
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER................................ 3-230
AFTER COLD WEATHER SEASON .............................................................................................. 3-230
PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-232
PREPARATION FOR LONG-TERM STORAGE ............................................................................. 3-232
MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-232
STARTING MACHINE AFTER LONG-TERM STORAGE ............................................................... 3-232
TROUBLES AND ACTIONS ................................................................................................................. 3-234
ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-234
PRECAUTIONS FOR TOWING MACHINE .................................................................................... 3-235
PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-236
OTHER TROUBLE......................................................................................................................... 3-239
MAINTENANCE............................................................................................................................................... 4-1
PRECAUTIONS FOR MAINTENANCE ..................................................................................................... 4-2
CHECK SERVICE METER READING ............................................................................................... 4-2
1-20
FOREWORD TABLE OF CONTENTS
KOMATSU GENUINE REPLACEMENT PARTS ................................................................................ 4-2

KOMATSU GENUINE LUBRICANTS ................................................................................................. 4-2
ALWAYS USE CLEAN WASHER FLUID ............................................................................................ 4-2
FRESH AND CLEAN LUBRICANTS .................................................................................................. 4-2
CHECK DRAINED OIL AND USED FILTER....................................................................................... 4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL .............................................................................. 4-2
PRECAUTIONS FOR ADDING DEF ................................................................................................. 4-2
WELDING INSTRUCTIONS............................................................................................................... 4-2
DO NOT DROP THINGS INSIDE MACHINE ..................................................................................... 4-2
PRECAUTIONS FOR KDPF .............................................................................................................. 4-3
PRECAUTIONS FOR SCR ASSEMBLY ............................................................................................ 4-3
DUSTY JOBSITES............................................................................................................................. 4-3
AVOID MIXING OIL............................................................................................................................ 4-3
LOCK INSPECTION COVERS .......................................................................................................... 4-3
PRECAUTIONS FOR OPENING AND CLOSING ENGINE SIDE COVER......................................... 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT ........................................................................................ 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ............................................................. 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE...................................................................... 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE........................................... 4-4
OUTLINE OF MAINTENANCE.................................................................................................................. 4-5
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
HANDLE ELECTRICAL COMPONENTS ........................................................................................... 4-9
HANDLE HYDRAULIC COMPONENTS............................................................................................. 4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ...............................................................4-11
MAINTENANCE SCHEDULE.................................................................................................................. 4-13
MAINTENANCE SCHEDULE TABLE............................................................................................... 4-13
MAINTENANCE PROCEDURE .............................................................................................................. 4-15
WHEN REQUIRED .......................................................................................................................... 4-15
CHECKS BEFORE STARTING........................................................................................................ 4-41
EVERY 50 HOURS MAINTENANCE ............................................................................................... 4-41
EVERY 250 HOURS MAINTENANCE ............................................................................................. 4-42
EVERY 500 HOURS MAINTENANCE ............................................................................................. 4-49
EVERY 1000 HOURS MAINTENANCE ........................................................................................... 4-55
SPECIFICATIONS ........................................................................................................................................... 5-1
SPECIFICATIONS .................................................................................................................................... 5-2
D65EX-18 SPECIFICATIONS ............................................................................................................ 5-2
D65PX-18 SPECIFICATIONS ............................................................................................................ 5-2
D65WX-18 SPECIFICATIONS ........................................................................................................... 5-3
ATTACHMENTS AND OPTIONS ..................................................................................................................... 6-1
GENERAL PRECAUTIONS ...................................................................................................................... 6-2
PRECAUTIONS FOR SAFETY .......................................................................................................... 6-2
HANDLE HYDRAULIC RIPPER................................................................................................................ 6-3
GENERAL VIEW................................................................................................................................ 6-3
EXPLANATION OF COMPONENTS .................................................................................................. 6-3
MACHINE OPERATIONS AND CONTROLS ..................................................................................... 6-4
TROUBLES AND ACTIONS .............................................................................................................. 6-6
HANDLE 3m WIDTH BLADE .................................................................................................................... 6-7
GENERAL VIEW................................................................................................................................ 6-7
MACHINE OPERATIONS AND CONTROLS ..................................................................................... 6-8
TRANSPORTATION........................................................................................................................... 6-8
CHECK AND MAINTENANCE ......................................................................................................... 6-10
SPECIFICATIONS ........................................................................................................................... 6-10
REPLACEMENT PARTS.................................................................................................................................. 7-1
1-21
TABLE OF CONTENTS FOREWORD
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS.......................................................................... 7-2

DEFINED LIFE PARTS LIST.............................................................................................................. 7-2
CONSUMABLE PARTS ............................................................................................................................ 7-3
CONSUMABLE PARTS ..................................................................................................................... 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .......................................................................... 7-6
LUBRICATION CHART ...................................................................................................................... 7-6
METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE ............................................................................................................................................. 7-9
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ............ 7-10
INDEX.............................................................................................................................................................. 8-1
1-22
SAFETY
Please read and make sure that you fully understand the precautions descri-
bed in this manual and the safety labels on the machine. When operating or
servicing the machine, always follow these precautions strictly.
2-1
SAFETY SAFETY
SAFETY
SAFETY LABELS ............................................................................................................................................ 2-4
LOCATION OF SAFETY LABELS............................................................................................................. 2-5
CONTENTS OF SAFETY LABELS ........................................................................................................... 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................................... 2-10
PRECAUTIONS BEFORE STARTING OPERATION............................................................................... 2-10
ENSURE SAFE OPERATION .......................................................................................................... 2-10
UNDERSTAND THE MACHINE ....................................................................................................... 2-10
PREPARATIONS FOR SAFE OPERATION ............................................................................................ 2-10
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT ................................................................. 2-10
INSPECT MACHINE ........................................................................................................................ 2-10
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT ............................................. 2-10
KEEP MACHINE CLEAN ................................................................................................................. 2-10
PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT .......................................................2-11
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ....................................................................2-11
IF ANY PROBLEM IS FOUND ..........................................................................................................2-11
PRECAUTIONS TO PREVENT FIRE.......................................................................................................2-11
ACTIONS IF FIRE OCCURS ............................................................................................................2-11
PREVENT FIRE............................................................................................................................... 2-12
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE.................................................................... 2-13
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE ..................................... 2-13
NO JUMPING ON OR OFF MACHINE............................................................................................. 2-14
LIFTING OF PERSONNEL PROHIBITED........................................................................................ 2-14
NO PEOPLE ON ATTACHMENTS ................................................................................................... 2-14
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT.............................................. 2-14
PRECAUTIONS WHEN LEAVING MACHINE .................................................................................. 2-14
EMERGENCY EXIT FROM OPERATOR'S CAB .............................................................................. 2-15
ELECTROMAGNETIC INTERFERENCE......................................................................................... 2-15
DO NOT GET CAUGHT IN WORK EQUIPMENT ................................................................................... 2-15
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................... 2-15
UNAUTHORIZED MODIFICATION ......................................................................................................... 2-16
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ........................................................... 2-16
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ............................................................ 2-16
PRECAUTIONS FOR OPERATION ............................................................................................................... 2-17
PRECAUTIONS FOR JOBSITE .............................................................................................................. 2-17
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS................................................................. 2-17
PRECAUTIONS WHEN WORKING ON LOOSE GROUND ............................................................. 2-17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES........................................................................ 2-17
ENSURE GOOD VISIBILITY............................................................................................................ 2-18
CHECK SIGNS AND SIGNALMAN'S SIGNALS............................................................................... 2-18
BEWARE OF ASBESTOS DUST ..................................................................................................... 2-19
START ENGINE...................................................................................................................................... 2-19
USE WARNING TAGS ..................................................................................................................... 2-19
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ........................................................ 2-19
PRECAUTIONS WHEN STARTING ENGINE .................................................................................. 2-20
IN COLD WEATHER........................................................................................................................ 2-20
START ENGINE WITH JUMPER CABLES ...................................................................................... 2-20
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-21
CHECKS BEFORE OPERATION..................................................................................................... 2-21
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE ............................................... 2-21
PRECAUTIONS WHEN TRAVELLING............................................................................................. 2-22
PRECAUTIONS WHEN TRAVELING ON SLOPES ......................................................................... 2-23
PRECAUTIONS WHEN OPERATING MACHINE............................................................................. 2-23
PROHIBITED OPERATIONS ........................................................................................................... 2-23
METHOD OF USING BRAKES ........................................................................................................ 2-23
PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES.................................. 2-23
PRECAUTIONS WHEN PARKING MACHINE ................................................................................. 2-24
2-2
SAFETY SAFETY
PRECAUTIONS FOR TRANSPORTATION............................................................................................. 2-24

PRECAUTIONS WHEN LOADING AND UNLOADING .................................................................... 2-24
TOWING AND BEING TOWED............................................................................................................... 2-25
PRECAUTIONS FOR TOWING AND BEING TOWED..................................................................... 2-25
PRECAUTIONS FOR MAINTENANCE .......................................................................................................... 2-26
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......................................... 2-26
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ....................................... 2-26
KEEP WORK PLACE CLEAN AND TIDY ........................................................................................ 2-26
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE .......................................... 2-26
ONLY AUTHORIZED PERSONNEL................................................................................................. 2-26
APPOINT LEADER WHEN WORKING WITH OTHERS .................................................................. 2-26
STABILITY ....................................................................................................................................... 2-26
GUARDS ......................................................................................................................................... 2-27
END OF SERVICE LIFE .................................................................................................................. 2-27
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ........................... 2-27
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING .......................................... 2-27
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS...................... 2-28
PRECAUTIONS FOR WORKING AT HIGH PLACES ...................................................................... 2-28
PRECAUTIONS WHEN WORKING ON MACHINE.......................................................................... 2-29
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT .......................... 2-29
USE PROPER TOOLS .................................................................................................................... 2-29
PRECAUTIONS FOR CHECK AND MAINTENANCE ............................................................................. 2-30
TURN BATTERY DISCONNECT SWITCH TO OFF POSITION ....................................................... 2-30
PRECAUTIONS FOR WELDING ..................................................................................................... 2-30
HANDLE BATTERY ......................................................................................................................... 2-30
PRECAUTIONS WHEN USING HAMMER ...................................................................................... 2-31
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT ............................................................... 2-31
PRECAUTIONS FOR HIGH-TEMPERATURE OIL........................................................................... 2-31
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS..................................................................... 2-32
PRECAUTIONS FOR HIGH-PRESSURE OIL.................................................................................. 2-32
PRECAUTIONS FOR HIGH-PRESSURE FUEL .............................................................................. 2-32
HANDLE HIGH-PRESSURE HOSES AND PIPING ......................................................................... 2-32
PRECAUTIONS FOR HIGH VOLTAGE............................................................................................ 2-33
PRECAUTIONS FOR NOISE........................................................................................................... 2-33
PRECAUTIONS FOR HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION .......... 2-33
DO NOT DISASSEMBLE RECOIL SPRING .................................................................................... 2-33
HANDLE ACCUMULATOR .............................................................................................................. 2-34
PRECAUTIONS FOR COMPRESSED AIR...................................................................................... 2-34
MAINTENANCE OF AIR CONDITIONER ........................................................................................ 2-34
CHEMICAL HAZARD....................................................................................................................... 2-34
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS .......................................................... 2-34
METHOD FOR SELECTING WINDOW WASHER FLUID................................................................ 2-35
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS................................................................. 2-35
PRECAUTIONS FOR DEF............................................................................................................................. 2-36
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING ......................................................... 2-36
PRECAUTIONS FOR ADDING ............................................................................................................... 2-36
PRECAUTIONS FOR STORING............................................................................................................. 2-36
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE ........................................................................... 2-36
OTHER PRECAUTIONS......................................................................................................................... 2-36
2-3
SAFETY LABELS SAFETY
SAFETY LABELS
k WARNING
Be sure that you fully understand the correct position, content and how to avoid a danger shown in the
safety labels.
Handle the warning signs and safety labels used on this machine as follows.
• Always keep the safety labels clean so that you can read it properly. When cleaning the safety labels, do
not use organic solvents or gasoline. These may cause the labels to peel off.
• If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details
of the part numbers for the safety labels, see this manual or the actual label, and place an order to your
Komatsu distributor.
• There are also other labels in addition to the warning signs and safety labels. Handle those labels in the
same way.
2-4
SAFETY SAFETY LABELS
LOCATION OF SAFETY LABELS
(1) Caution for operation, inspection and maintenance (9) Caution for approaching while moving machine
(2) Caution before moving in reverse (10) Prohibition of start by short-circuiting
(3) Caution when leaving the operator's seat (11) Caution for handling ROPS/FOPS
(4) Caution for high-temperature coolant and hydraulic (12) Caution for blast site
oil (13) Caution for high-temperature parts
(5) Caution for handling accumulator (14) Caution for handling DEF
(6) Caution for adjusting track tension (15) Caution for handling seat belt
(7) Caution for handling cable
(8) Stop rotation during inspection and maintenance
2-5
CONTENTS OF SAFETY LABELS

(1) Caution for operation, inspection and maintenance (09651-
A0641)
• Warning !
• Read manual before operation, maintenance, disassembly,
assembly and transportation.
(2) Caution for safety at rear (09802-B0640)

• Sign indicates a hazard of rear working and advancing be-
hind.
• Read manual before operation.
k WARNING
To prevent SEVERE INJURY or DEATH, do the following
before moving machine or its attachments :
• Honk horn to alert people nearby.
• Be sure no one is on or near the machine.
• Use spotter if view is obstructed.
Follow above even if the machine is equipped with back-up
alarm and mirrors.
09802-B0640
(3) Caution when leaving the operator's seat (09654-B0641)

• Sign indicates a hazard of unexpected moving of stopped
machine.
• Lower working device to ground, move safety lever to lock
position and take engine key with you before leaving ma-
chine.
2-6
(4) Caution for high-temperature coolant and hydraulic oil

(09653-A0481)
• Never remove the cap when the engine is at operating
(high) temperature. Steam or high temperature oil blowing
up from the radiator or hydraulic tank, will cause personal
injury and/or burns.
• Never remove the radiator cap or hydraulic tank oil filter
when cooling water or hydraulic oil is at high temperatures.
(5) Caution for handling accumulator (09659-A057B)

• There is the hazard of explosion causing injury.
• Do not disassemble the accumulator, make holes in it,
weld it, or bring it near flame.
(6) Caution for adjusting track tension (09657-A0881)

This safety label is attached to the back of the track adjustment
window cover.
• Sign indicates a hazard of flying plug from track adjuster
that could cause injury.
• Read manual and adjusting track for safe and proper han-
dling.
(7) Caution for handling cable (09808-A0881)

• Sign indicates an electric hazard handling the cable.
• Read manual for safe and proper handling.
(8) Stop rotation during inspection and maintenance (09667-

A0481)
• Sign indicates a hazard of rotating parts, such as belt.
• Turn off before inspection and maintenance.
2-7
(9) Caution for approaching while moving machine (09806-

B1683)
• Sign indicates a hazard of being run over by moving equip-
ment.
• Keep a safe distance from equipment when it is moving.
(10) Prohibition of start by short-circuiting (09842-A0481)

• Start the engine only after sitting down in the operator's
seat.
• Do not attempt to start the engine by short-circuiting the
engine starting circuit. Such an act may cause a serious
bodily injury or fire.
(11) Caution for handling ROPS/FOPS (09620-A3001, 09620-

A2001)
ROPS/FOPS CERTIFCATION
This protective structure complies with the standard provided
that it is properly equipped on the machine which mass is less
than the specified maximum mass.
• If some modification is applied to the ROPS or FOPS, it
may effect the strength and may not comply with the
standard. Do not drill, cut or weld on the ROPS or FOPS structure. Consult Komatsu Distributor before al-
tering.
• ROPS or FOPS may provide less protection if it has been structurally damaged or involved roll-over. Con-
sult Komatsu Distributor in that case.
• Always wear seat belt when moving.
(12) Caution for blast site (09845-00480)
(only when equipped with KOMTRAX)
• Sign indicates an explosion hazard caused by active radio
transmitter at a blast zone.
• Keep machine at a safe distance from a blast zone and
detonator.
2-8
(13) Caution for high-temperature parts (6166-15–9990)

• Sign indicates a burn hazard from touching heated parts,
such as engine, motor or muffler during or right after oper-
ation.
• Never touch when hot.
(14) Caution for handling DEF (09632-61480)

• To avoid engine damage or fire, fill with DEF only.
• Never use diesel fuel.
(15) Caution for using seat belt (09848-A0480)

• Always use seat belt when operating the machine to re-
duce risk of injury or death in case of a roll-over.
• Always check for damage or wear of the seat belt, damage
of the connecting brackets, and tightness of bolts.
• Adjust seat position to allow full brake pedal travel with op-
erator's back against seat back.
• After adjusting seat position, get off the seat and tighten
the tether belts located between the floor and seat if equip-
ped.
• Read Operation and Maintenance Manual.
2-9
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE-
NANCE SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION

AND MAINTENANCE
Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per-
forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine
carefully and obey the warnings.
PRECAUTIONS BEFORE STARTING OPERATION

ENSURE SAFE OPERATION
• Only trained and authorized personnel can operate and maintain the machine.
• Follow all safety, precautions, and instructions in this manual when operating or performing inspection or
maintenance on the machine.
• If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely
operate or repair your machine may be severely impaired, putting yourself and everyone else on your job
site in danger.
• When working with another operator or with the person on the worksite traffic duty, discuss the content of
the operation beforehand and use the determined signals when performing the operation.
UNDERSTAND THE MACHINE

Before operating the machine, read this manual thoroughly. If there is any place in this manual that you do not
understand, ask the person in charge of safety for explanation.
PREPARATIONS FOR SAFE OPERATION

PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT
• Be sure that all guards, covers, cameras, and mirrors are in their proper position. Repair them immediately
if they are damaged.
• Understand the using method of the safety related devices and use them properly.
• Never remove any safety related devices. Always keep them in good operating condition.
INSPECT MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until re-
pairs of the problem location have been completed.
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

• Do not wear loose clothes or any accessories. If any of
these catch the control levers or protruding parts, it may
cause the machine to move unexpectedly, it is extremely
dangerous.
• Always wear a hard hat and safety shoes. Wear protective
eyeglasses, mask, gloves, ear plugs, and safety belt as
appropriate for the work function.
• Long hair hanging out from the hard hat is dangerous that
it may get caught up in the machine. Tie the hair up and be
careful not to be caught.
• Check that all personal protective items function properly
before using them.
KEEP MACHINE CLEAN

• If you get on or off the machine or perform inspection and maintenance on the machine with mud or oil, you
may slip and fall, and it is dangerous. Wipe off any mud or oil from the machine. Always keep the machine
clean.
2-10
SAFETY NANCE
• If water gets into the electrical system, electric devices will

cause malfunctions, and the machine will cause error. If
the machine cause error, it may move unexpectedly and
cause serious personal injury or death. When washing the
machine with water or steam, do not allow the water or
steam to come into direct contact with electrical compo-
nents.
• If high-pressure water is sprayed directly onto camera, it
may cause failure. Do not allow the high-pressure water to
get into camera directly. When cleaning the camera, wipe
off any dirt with soft cloth.
• When cleaning camera and mirror, if you stand on an unstable place, or take an unstable posture, you may
fall and be injured. Put proper stepladder or step on the level and firm ground, and clean the camera and
mirror in secure posture.
PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT

• When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.
If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a seri-
ous accident.
• Do not leave tools or machine parts lying around inside the operator's compartment. If tools or parts get into
the control devices, it may obstruct operation and cause the machine to move unexpectedly, resulting in
serious personal injury or death.
• Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
• Do not use a cellular phone when driving or operating the machine. This may lead to mistakes in operation,
and may cause serious personal injury or death.
• Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Observe the following precautions to prepare for action if any
serious personal injury or death 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
for the possibility of fires.
• Perform periodic inspection and maintenance to ensure
that the fire extinguisher can always be used.
• Provide a first aid kit in the storage point. Perform periodic
checks and add to the contents if necessary. ,&
IF ANY PROBLEM IS FOUND

If you find any problem in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the per-
son in charge and take the necessary action. Do not operate the machine until the problem has been corrected.
PRECAUTIONS TO PREVENT FIRE

ACTIONS IF FIRE OCCURS
• Turn the starting switch to OFF position, and stop the engine.
• Use the handrails and steps to escape from the machine.
• Do not jump off the machine. There is the danger of falling and it may cause personal injury.
• The fume generated by a fire contains harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
2-11
NANCE SAFETY
• After a fire, harmful compounds may be left. If it touches your skin, it may have a bad influence on your
body.
Be sure to wear rubber gloves when handle the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.
PREVENT FIRE
Fire caused by fuel, oil, coolant, or window washer fluid
Do not bring any open flame close to flammable substances
such as fuel, oil, coolant, or window washer fluid. There is a
danger that they may catch fire. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
,&
• Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other combustible materials into a
safe container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel fuel or gasoline. There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain combustible liquids. ,&
• Determine well-ventilated areas for storing oil and fuel.
Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation of combustible material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other combustible materials accumulated
or affixed around the engine exhaust manifold, muffler, or battery, or inside the undercovers.
• To prevent fires from spreading sparks or burning particles from other fires, remove any combustible materi-
als such as dry leaves, chips, pieces of paper, coal dust, or any other combustible materials accumulated
around the cooling system (radiator, oil cooler) or inside the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused from piping
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury.
Fire around the machine due to highly heated exhaust gas
This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF).
2-12
SAFETY NANCE
KDPF is a device to purify the soot in the exhaust gas. Exhaust gas temperature may increase during the purifi-
cation process (regeneration). Do not bring any combustible material close to the outlet of the exhaust pipe.
When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to the regener-
ation disable to prevent fire hazards due to highly heated exhaust gas during the aftertreatment devices regen-
eration. For setting, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-104)”.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-
tions.
• When taking the electrical power for the lighting equipment from the machine, see “POWER SUPPLY OUT-
LET (3-98)”.
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE
To prevent personal injury caused by slipping or falling off the machine, always observe the following.
• Use the handrails and steps indicated by arrow A in the
figure when getting on or off the machine.
Use the handrails and steps indicated by arrow B only
when moving along the top of the track or when checking
or performing maintenance inside the side cover, or when
filling the tank with oil. Never use them when getting on or
off the machine.
(Power angle power tilt dozer)
2-13
NANCE SAFETY
• Always face the machine and maintain at least three-point

contact (both feet and one hand, or both hands and one
foot) with the handrails and steps to ensure that you sup-
port yourself.
• Before getting on and off the machine, check the handrails
and steps if there is any oil, grease, or mud on them. Wipe
it off immediately not to slip if any. In addition, tighten any
loose bolt of the handrails and steps.
If the handrails and steps are damaged or deformed, they
need to be repaired immediately. Ask your Komatsu dis- ,&
tributor to perform this work.
• Do not grip the control levers, parking brake lever, or work equipment lock lever when getting on or off the
machine. When getting on or off the machine, take care that your body or clothes do not touch the control
levers.
• Never climb on the engine hood or covers where there are no non-slip pads.
• Do not get on or off the machine with tools in your hand.
NO JUMPING ON OR OFF MACHINE

Getting on or off the moving machine can cause serious personal injury or death. Always observe the following.
• Never jump on or off the machine. Never get on or off a moving machine.
• If the machine starts to move when there is no operator on the machine, do not jump on to the machine and
try to stop it.
LIFTING OF PERSONNEL PROHIBITED

Under no circumstances should this machine be used for the lifting of personnel.
NO PEOPLE ON ATTACHMENTS
Never let anyone ride on the work equipment or other attachments. There is a hazard of falling and suffering
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

When standing up from the operator's seat to adjust the opera-
tor's seat, always lower the work equipment completely to the
ground, set work equipment lock lever (1) and parking brake
lever (2) to LOCK position (L), and stop the engine.
If the control levers are touched by mistake, there is a danger
that the machine may suddenly move and cause serious per-
sonal injury or death.
PRECAUTIONS WHEN LEAVING MACHINE

If the proper procedures are not taken when parking the machine, the machine may suddenly move off by itself,
and this may lead to serious personal injury or death. Always observe the following.
2-14
SAFETY NANCE
• When leaving the machine, always lower the work equip-

ment completely to the ground, set work equipment lock
lever (1) and parking brake lever (2) to LOCK position (L),
and stop the engine.
• When the operator's seat and console are located in front,
your body or clothes will easily touch the levers. Shift them
backward to keep enough space, and then get off the ma-
chine.
• Lock all places and always take the key with you and keep
it in the specified location.
EMERGENCY EXIT FROM OPERATOR'S CAB

The machine equipped with the cab has the doors on its right and left sides. If either door does not open, es-
cape from the other door.
ELECTROMAGNETIC INTERFERENCE
When the machine is operating close to a source of high electromagnetic interference, such as a radar station,
some abnormal phenomena may be observed.
• The display on the monitor panel may behave erratically.
• The warning buzzer may sound.
These effects do not signify a malfunction and the machine will return to normal as soon as the source of inter-
ference is removed.
DO NOT GET CAUGHT IN WORK EQUIPMENT

The clearance in the area around the work equipment changes according to the movement of the link. If you are
caught, this may lead to serious personal injury or death. Do not allow anyone near any of the rotating or tele-
scopic parts.
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

The operator's compartment is equipped with a structure (such as ROPS, FOPS) to protect the operator by ab-
sorbing the impact energy.
2-15
NANCE SAFETY
As for the machine equipped with ROPS, if the machine weight

(mass) exceeds the certified value (shown on ROLL-OVER
PROTECTIVE STRUCTURE (ROPS) CERTIFICATION plate),
ROPS will not be able to fulfill its function. Do not increase ma-
chine weight beyond the certified value by modifying the ma-
chine or by installing attachments to the machine.
Also, if the function of the protective equipment is impeded, the
protective equipment will not be able to protect the operator,
and the operator may suffer injury. Always observe the follow-
ing. ,&
• If the machine is equipped with a protective structure, do

not remove the protective structure and perform operations without it.
• If the protective structure is welded, or holes are drilled in it, or it is modified in any other way, its strength
may drop. Any modification is prohibited.
• If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be
reduced and it will not be able to fulfill its function properly. In such cases, always consult your Komatsu
distributor.
• Even if the protective structure is installed, always fasten your seat belt properly when operating the ma-
chine. If you do not fasten your seatbelt properly, it cannot display its effect.
Always fasten your seat belt while operating the machine.
UNAUTHORIZED MODIFICATION
• Komatsu will not be responsible for any personal injuries, product failures, physical loss or damage, or influ-
ence on the environment resulting from modifications made without authorization from Komatsu.
• Any modification made without authorization from Komatsu can create hazards. Before making a modifica-
tion, consult your Komatsu distributor.
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

• Any personal injuries, product failures, physical loss or damage, or influence on the environment resulting
from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.
• When installing optional parts or attachments, contact your Komatsu distributor for advice to any potential
problems or safety and legal requirements.
• When installing and using optional attachments, always read the instruction manual for the attachment, and
the general information related to attachments in this manual.
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING

The engine exhaust gas contains substances that may damage
your health or even cause death. Start or operate the engine in
a place where there is good ventilation. If the engine or ma-
chine must be operated inside a building or underground,
where the ventilation is poor, take steps to ensure that the en-
gine exhaust gas is removed and that ample fresh air is
brought in.
,&
2-16
SAFETY PRECAUTIONS FOR OPERATION
PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR JOBSITE
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS
On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start-
ing operations, always check the following to confirm that there is no danger on the jobsite.
• Always be careful when performing operations near materials such as thatched roofs, dry leaves or dry
grass, because they are easily combustible and may cause fire.
• Check the terrain and condition of the ground at the jobsite, and determine the safest method of operation.
Do not operate in a dangerous area where landslides or rockfall may occur.
• If water lines, gas lines, or high-voltage electrical lines may
be buried under the jobsite, contact the management com-
pany to identify their locations, and be careful not to dam-
age any of these lines.
• Take necessary measures to prohibit other personnel from
coming close to the machine during operation.
• In particular, if you need to operate on a road, protect pe-
destrian and cars by designating a person for jobsite traffic
duty or by installing fences around the jobsite.
• When traveling or operating in shallow water or on soft
ground, check the water depth, speed of the current, con-
dition of bedrock, and shape of the ground beforehand. Al-
ways avoid any place that will obstruct travel.
PRECAUTIONS WHEN WORKING ON LOOSE GROUND

• Avoid driving or operating the machine near the edge of cliffs, road edges, and deep ditches. The ground
may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil is weak in these areas, after
heavy rain or blasting or after earthquakes.
• When working on embankments or near excavated ditches, there is a hazard that the weight and vibration
of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the
ground is safe and to prevent the machine from rolling over or falling.
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause
serious personal injury or death. On jobsites where the machine may go close to electric cables, always observe
the following.
• Before starting work near electric cables, inform the local
power company of the work to be performed, and ask
them to take the necessary action.
• Even going close to high-voltage cables can cause electric
shock. Always maintain a safe distance (see the table) be-
tween the machine and the electric cable. Check with the
local power company about the voltage of cables and safe
operating procedure before starting operations.
Voltage of Cables Safety Distance
100V, 200V Min. 2 m
6600V Min. 2 m
22000V Min. 3 m
66000V Min. 4 m
2-17
PRECAUTIONS FOR OPERATION SAFETY
Voltage of Cables Safety Distance

154000V Min. 5 m
187000V Min. 6 m
275000V Min. 7 m
500000V Min. 11 m
• To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera-
tor's seat, and be careful not to touch the chassis with any exposed part of your body.
• Use a signalman to give warning if the machine approaches too close to the electric cables.
• When performing operations near high voltage cables, prohibit anyone other than related persons to come
close to the machine during operation.
• If the machine should come too close or touch the electric cable, to prevent electric shock, the operator
should not leave the operator's compartment until it has been confirmed that the electricity has been shut
off. Also, prohibit any other persons to come close to the machine.
ENSURE GOOD VISIBILITY

Although this machine is equipped with mirrors and cameras to ensure good visibility, there are places that can-
not be seen from the operator's seat. Be careful when performing operation.
When driving the machine or performing operations in places with poor visibility, it is dangerous and may cause
serious personal injury or death because it is difficult to check for obstacles and condition of the jobsite. When
driving the machine or performing operations in places with poor visibility, always observe the following.
• Allocate a signalman for jobsite duty if there are areas where the visibility is poor.
• Only one signalman should give signals.
• When working in dark places, turn on the working lamp and headlamps installed to the machine, and set up
additional lighting in the work area if necessary.
• Stop operations if the visibility is poor because of mist, snow, rain, or dust.
• When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror to
ensure good visibility.
• When cleaning the camera, wipe off any dirt with soft cloth. Make sure that a clear view is displayed on the
monitor.
When cleaning camera, if you stand on an unstable place, or take an unstable posture, you may fall and be
injured. Put proper stepladder or step on the level and firm ground, and clean the camera in secure posture.
CHECK SIGNS AND SIGNALMAN'S SIGNALS

If signals and labels are not clear, serious personal injury can result from downward slip, overturn or accidental
contact with nearby people or obstacles. Always observe the following.
• Set up labels to inform of road edges and soft ground. If the visibility is not good, position a conductor if
necessary. Operator should pay careful attention to the labels and follow the instructions from the conduc-
tor.
• Only one signalman should give signals.
• Make sure that all workers understand the meaning of all signals, signs, and labels before starting work.
2-18
BEWARE OF ASBESTOS DUST

Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsite
where demolition work is performed or industrial waste is han-
dled. Always observe the following.
• Spray water to keep down the dust.
• Do not use compressed air.
• If there is danger that there may be asbestos dust in the
air, always operate the machine from an upwind position,
and make sure that all workers operate on the upwind ,&
side.
• All workers should use anti-dust masks.
• Prohibit other personnel from coming close to the machine during operation.
• Always observe the regulations for jobsite and environmental standards.
This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing
asbestos. Always use Komatsu genuine parts.
START ENGINE
USE WARNING TAGS
If there is a “DANGER! Do NOT operate!” warning tag dis-
played, it means that someone is performing inspection and
maintenance of the machine. If the warning tag is ignored and
the machine is operated, the person performing inspection or
maintenance may be caught in the rotating parts or moving
parts. It is dangerous and may cause serious personal injury or
death. Do not start the engine or touch the levers.
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE

Perform the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If these checks are not performed properly, problems may occur
with the operation of the machine, and there is a danger which may lead to serious personal injury or death.
• Remove all dirt from the surface of the window glass to ensure a good view.
• Perform the walk-around check.
• Remove all dirt from the surface of the lens of the headlamps and working lamps, and check that they light
up correctly.
2-19
• Check the coolant level, fuel level, DEF level, and oil level in engine oil pan, check for clogging of the air
cleaner, and check for damage to the electric wiring.
• Check that there is no mud or dust accumulated around the movable parts of any pedals, and check that
the pedals work properly.
• Adjust the operator's seat to a position for easier operation. Check that there is no damage or wear to the
seat belt or mounting clamps.
• Check that the gauges and camera view work properly, check the angle of the mirror, and check that the
control levers are all at NEUTRAL position.
• Before starting the engine, check that work equipment lock
lever (1) and parking brake lever (2) are in LOCK positions
(L).
• Adjust the mirrors to have a good rear view and a good
view of surrounding area from the operator's seat.
For the adjustment, see “METHOD FOR ADJUSTING
MIRRORS”.
• If the machine is equipped with cameras, adjust the cam-
eras to have a good rear view and a good view of sur-
rounding area from the operator's seat.
For the adjustment, please contact your Komatsu distribu-
tor.
• Check that there are no persons or obstacles above, be-
low, or in the area around the machine.
PRECAUTIONS WHEN STARTING ENGINE

The machine may suddenly move off and this may lead to serious personal injury or death. Always observe the
following.
• Start the engine only while sitting down in the operator's seat.
• When starting the engine, sound the horn as a warning.
• Prohibit other personnel to get on the machine.
• Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious
personal injury or death.
IN COLD WEATHER
• If the warm-up operation is not performed thoroughly, and the work equipment is operated, the reaction of
the work equipment to the operation of the control levers and pedals will be slow and the movement of it
may not be what the operator intended. Be sure to perform the warm-up operation. Particularly in a cold
weather, be sure the warming-up operation is completed.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power
source. There is a hazard that this will ignite the battery and cause the battery to explode.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check
that there is no leakage of electrolyte before starting.
START ENGINE WITH JUMPER CABLES

If any mistake is made in the method of connecting the jumper cables, it may cause the battery to explode, so
always observe the following.
2-20
• Always wear protective eyeglasses and rubber gloves

when starting the engine by using the jumper cables.
• When connecting a normal machine to a failed machine
with the jumper cables, always use the normal machine
with the same battery voltage as the failed machine.
• When starting the engine with the jumper cables, perform
the starting operation with two workers (one worker sitting
in the operator's seat and the other working with the bat-
tery).
• When starting from another machine, be careful that the
normal machine does not contact with the failed machine.
• When connecting the jumper cables, turn the starting switch to OFF position for both the failed machine and
the normal machine. If the failed machine has a battery disconnect switch, turn it to OFF position, and turn
it ON again after connecting the cables.
For details of operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-102)”.
It is dangerous that the machine may move when the power is connected.
• Be sure to connect the positive (+) cable first when installing the jumper cables. Disconnect the negative (-)
cable (ground side) first when removing them.
• When disconnecting the jumper cables, take care not to bring the clips in contact with each other or with the
machine.
• For the starting procedure with the jumper cables, see OPERATION, “START ENGINE WITH JUMPER CA-
BLES (3-238)”.

CHECKS BEFORE OPERATION
If the checks before starting are not performed properly, the machine will be unable to display its full perform-
ance. It is dangerous and may cause serious personal injury or death.
When performing the checks, move the machine to a wide area with no obstructions, and pay careful attention
to the surroundings. Prohibit other personnel from coming close to the machine during checks.
• Fasten the seatbelt. When the brakes are applied sudden-
ly, the operator may be thrown out of the operator's seat. It
is dangerous and may cause personal injury.
• Check the operating condition of the machine, work equip-
ment, and travel and brake systems.
• Check for any problem in the sound, vibration, heat and
smell of the machine, or abnormalities of instruments. Also
check that there is no leakage of oil or fuel.
• If any problem is found, repair it immediately.
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

• Always lock all the doors and windows of the operator's compartment in position regardless of whether it is
open or closed.
Always close all the windows and doors on jobsites where there is danger of scattering fragments, and
things which may intrude into operator's cab.
• Prohibit other personnel to get on the machine.
2-21
• If there are any persons in the area around the machine,

there is danger that they may be hit or caught by the ma-
chine, and this may lead to serious personal injury or
death. Always observe the following before traveling.
• Always operate the machine only when seated on the
operator's seat.
• Before starting to move, check again that there is no
people or obstacle in the surrounding area.
• Before moving, sound the horn to warn people in the
surrounding area.
• Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly.
• If there is an area in the rear of the machine which cannot be seen, position a signalman. Travel slowly
and be extremely careful not to hit any person or object.
Always be sure to perform the above precautions even when the machine is equipped with mirrors and cam-
eras.
PRECAUTIONS WHEN TRAVELLING

Serious personal injury or death can result from tipping over of the travelling machine or its accidental contact.
Always observe the following.
• When driving the machine or performing operations, always keep a safe distance from people, structures,
or other machines to avoid coming into contact with them.
• Never turn the key in the starting switch to OFF position when the machine is travelling. If the engine stops
when the machine is travelling, it may become impossible to operate the steering, and this may cause seri-
ous personal injury or death. If the engine stops, depress the brake pedal immediately to stop the machine.
• When travelling on a level ground, keep the work equip-
ment approximately 40 to 50 cm above the ground. If that
height is not maintained between the work equipment and
the ground, the work equipment may get stuck in the
ground and the machine may tip over.
• Try to avoid travelling over obstacles. If the machine has to

travel over an obstacle, keep the work equipment close to
the ground and travel at low speed. The machine tips over
easily to the right or left. Do not drive it over obstacles
which make the machine tilt largely to the right or left.
• When driving the machine on the rough ground, drive it at
low speed and do not operate the steering suddenly. There
is a danger that the machine may tip over. The work equip-
ment may hit the ground, and the machine may lose its
balance, or it may damage the machine or structures in the
area.
• When using the machine, to prevent serious personal injury or death caused by the work equipment or by
the machine tipping over due to overloading, do not use the machine beyond the permitted performance of
the machine such as the maximum permitted load for the structure of the machine.
• When passing over bridges or structures, check first that the structure is strong enough to support the
weight of the machine.
• When operating in tunnels, under bridges, under electric wires, or other places where the height is limited,
operate slowly and be extremely careful not to let the machine body or work equipment hit anything.
2-22
PRECAUTIONS WHEN TRAVELING ON SLOPES

To prevent the machine from tipping over or slipping to the side, always observe the following.
• Never turn the key in the starting switch to OFF position
when the machine is traveling downhill. If the engine stops
when the machine is traveling, it may become impossible
to operate the steering, and this may cause serious per-
sonal injury or death. If the engine stops, depress the
brake pedal immediately to stop the machine.
• Keep the work equipment approximately 20 to 30 cm
above the ground. In case of emergency, lower the work
equipment to the ground immediately to help stop the ma-
chine.
• Always drive the machine straight up or down a slope.
Driving the machine at an angle or across the slope is extremely dangerous.
• Do not turn on slopes or drive across slopes. Always go down to a flat place to change the position of the
machine, then drive it on to the slope again.
• Do not drive the machine on a slope covered with the steel plates. Even with slight slopes there is a hazard
that the machine may slip.
• Drive the machine at low speed on the grass or fallen leaves. Even with slight slopes, there is a hazard that
the machine may slip.
• When traveling downhill, never shift gear or place the transmission at neutral. Engine brake does not work
and dangerous. Always set the transmission to a low gear before starting to travel downhill.
• Depress the brake pedal or use the engine brake as necessary.
PRECAUTIONS WHEN OPERATING MACHINE

• Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when
dropping soil over a cliff, dump one pile, then use the next pile of soil to push the first pile.
• The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the
top of a slope. When this happens, there is danger that the travel speed will suddenly increase, so be sure
to reduce the speed.
• If the machine moves with only either side of the blade loaded, its tail may swing. Take care.
PROHIBITED OPERATIONS
When using the machine, to prevent serious personal injury or death caused by the work equipment or by the
machine tipping over due to overloading, do not use the machine beyond the permitted performance of the ma-
chine such as the maximum permitted load for the structure of the machine.
METHOD OF USING BRAKES

• Do not put your foot on the brake pedal unnecessarily. If the machine travels with your foot on the brake
pedal, the brake operates constantly and heats abnormally, and is disabled and that can cause an accident.
• Do not depress the brake pedal repeatedly more than necessity.
• Use the engine brake during downhill travel.
PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES

• Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ma-
chine, and do not perform abrupt lever operation. Machine may slip even on a slight slope. Be particularly
careful when working on slopes.
• Frozen road becomes soft when the temperature rises, and the machine may tip over or be not able to es-
cape. Be particularly careful when working on frozen road.
• It is dangerous that the machine enters deep snow. The machine may tip over or become buried in the
snow. Be careful not to go off the road or to get trapped in a drift of snow.
• When performing snow removal, the road and objects placed beside the road are buried in the snow and
cannot be seen. Be careful.
2-23
• When traveling on snow-covered slopes, never apply the foot brake suddenly. Reduce the speed and use
the engine brake while applying the foot brake intermittently (depress the brake intermittently several
times). If necessary, lower the work equipment to the ground to stop the machine.
PRECAUTIONS WHEN PARKING MACHINE

Unexpected move of the parked machine can cause serious personal injury or death. Always observe the fol-
lowing.
• Park the machine on a firm, level ground.
• Select a place where there is no hazard of landslides, falling rocks, or flooding.
• Lower the work equipment to the ground.
• When leaving the machine, set work equipment lock lever
(1) and parking brake lever (2) to LOCK position (L), and
stop the engine.
• When the operator's seat and console are located in front,
your body or clothes will easily touch the levers. Shift them
backward to keep enough space, and then get off the ma-
chine.
• Always close the operator's cab door, and use the key to
lock all the equipment in order to prevent any unauthorized
person from moving the machine. Always remove the key,
take it with you, and keep it in the specified place.
• If it is necessary to park the machine on a slope, always

observe the following.
• Set the work equipment on the downhill side and dig it
into the ground.
• In addition, block the tracks from movement.
PRECAUTIONS FOR TRANSPORTATION

When the machine is transported on a trailer, serious personal injury or death may result because of the acci-
dent during transportation. Always observe the following.
• Always check the machine dimensions carefully. Depending on the work equipment and optional devices
installed, the machine weight, transportation height, and overall length differ.
• Check beforehand that all bridges and other structures on the transportation route are strong enough to
withstand the combined weight of the transporter and the machine being transported.
• This machine may need to be divided into components for transportation depending on the regulation.
When transporting the machine, consult your Komatsu distributor.
PRECAUTIONS WHEN LOADING AND UNLOADING

If handling is wrong when loading or unloading the machine, it is dangerous that the machine may tip over or
fall. It requires particular attention. Always observe the following.
• Perform loading and unloading on a firm, level ground only. Avoid road edge or place near the cliff.
2-24
• Always use ramps of adequate strength. Be sure that the

ramps are wide, long, and thick enough to provide a safe
loading slope. Take suitable steps to prevent the ramps
from moving out of position or coming off.
(1) Chocks
(2) Ramp
(3) Center of ramp
(4) Angle of ramp: Max. 15 °.
• Be sure the ramp surface and the platform of trailer are
clean and free of grease, oil, ice, water and other loose
materials. If any, remove them. Remove dirt around the undercarriage of the machine. On a rainy day, in
particular, be extremely careful since the ramp surface is slippery.
• Run the engine at low idle and drive the machine slowly at low speed.
• When on the ramps, do not operate any lever except for the travel lever (travel forward and reverse).
• Never correct your steering on the ramps. If necessary, drive off the ramps onto the ground, correct the di-
rection, then enter the ramps again.
• The center of gravity of the machine will change suddenly at the joint between the ramps and the loading
platform, and there is danger of the machine losing its balance. Drive slowly over this point.
• When loading or unloading to an embankment or platform, make sure that it has suitable width, strength,
and grade.
• For machines equipped with a cab, always lock the door after loading the machine. The door may open
during transportation.
• When it is necessary to remove handrails and steps, take care not to lose removed handrails and steps.
Install the removed handrails and steps securely.
TOWING AND BEING TOWED

PRECAUTIONS FOR TOWING AND BEING TOWED
Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or
drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or
death.
For towing, see“PRECAUTIONS FOR TOWING MACHINE (3-235)”
• Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the ma-
chine being towed.
• Never use the wire rope which has cut strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
• Always wear leather gloves when handling the wire rope.
• Never tow a machine on a slope.
• During the towing operation, never stand between the tow-
ing machine and the machine being towed.
2-25
PRECAUTIONS FOR MAINTENANCE SAFETY
PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE
During inspection and maintenance, always display the “DAN-
GER! Do NOT operate!” warning tag.
If there is a “DANGER! Do NOT operate!” warning tag dis-
played, it means that someone is performing inspection and
maintenance of the machine. If the warning tag is ignored and
the machine is operated, the person performing inspection or
maintenance may be caught in the rotating parts or moving
parts. It is dangerous and may cause serious personal injury or
death. Do not start the engine or touch the levers.
If necessary, put up signs around the machine as well.
Warning tag part No. 09963-A1640
When not using this warning tag, keep it in the toolbox. If there
is no toolbox, keep it in the pocket for Operation and Mainte-
nance Manual.
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 perform operations safely.
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure your-
self.
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE

• Stop the machine on a firm, level ground.
• Select a place where there is no hazard of landslides, falling rocks, or flooding.
ONLY AUTHORIZED PERSONNEL

As long as maintenance of the machine is continued, do not allow unauthorized person to come near the work-
place. They might get unexpected personal injury from, for instance, touching machine. Do not allow anyone
except the workers concerned to enter the workplace. If necessary, employ a guard.
APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow
his/hers instructions during the operation in order to prevent personal injuries caused by being caught or
pinched.
STABILITY
• When dismantling or assembling the machine for the purpose of maintenance, repair or transportation, al-
ways ensure that at each stage of the process, care is taken to ensure that the machine remains stable.
Failure to do this could result in serious injury or death.
2-26
SAFETY PRECAUTIONS FOR MAINTENANCE
GUARDS
• Guards are installed in the area of the engine to protect personnel from moving parts. These guards should
only be removed by Komatsu service engineer unless specific instructions are given in this manual.
END OF SERVICE LIFE

• For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor.
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or
high-pressure liquids, it is dangerous and may cause serious personal injury or death. Always observe the fol-
lowing.
• Lower the work equipment completely to the ground and
stop the engine before performing any inspection and
maintenance.
• Turn the starting switch to ON position, set work equip-

ment lock lever (2) to FREE position (F), operate the blade
control lever to RAISE and LOWER position a few times
repeatedly to release the remaining pressure in the hy-
draulic circuit, then set parking brake lever (1) and work
equipment lock lever (2) to LOCK position (L).
• Check that the battery relay is off and main power is not
conducted. (After turning the starting switch to OFF posi-
tion, wait for approximately 1 minute and press the horn
switch. If the horn does not sound, power is not conduct-
ed.)
• Block the tracks from movement.
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent accident, do not perform maintenance with the engine running. When it is necessary to perform the
maintenance with the engine running, always observe the following.
• 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.
2-27
• Rotating parts such as the fan, fan belt are dangerous that
they may easily catch a body part or an object someone
wears. Be careful not to come close to the rotating part.
• Never drop or insert tools or other objects into the fan, fan
belt, or other rotating parts. They may contact the rotating
parts and break, and be scattered. It is dangerous.
• If the automatic active regeneration of KDPF starts during
maintenance work, surroundings of KDPF become high
temperature. When performing maintenance work, perform ,&
the aftertreatment devices regeneration disable according
to “HANDLE Komatsu Diesel Particulate Filter (KDPF)
(3-104)”.
• Set work equipment lock lever (1) and parking brake lever
(2) to LOCK positions (L) to prevent the work equipment
from moving.
• Do not touch the control levers. When it is necessary to
operate the control levers, always give a signal to your fel-
low workers to evacuate them to a safe place.
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS

• Appoint a leader before starting removal or installation operations for attachments.
• Place attachments that have been removed from the ma-
chine in a stable condition so that they do not fall. And take
steps to prevent unauthorized persons from entering the
storage area.
,&
PRECAUTIONS FOR WORKING AT HIGH PLACES

When working at high places, use a step ladder or other stand to ensure that the work can be performed safely.
There is a danger falling from high place that can lead to serious personal injury or death.
2-28
PRECAUTIONS WHEN WORKING ON MACHINE

• When performing maintenance work on the machine,
maintain the foothold clean and orderly to prevent falling.
Always observe the followings.
• Avoid spilling of oil and grease.
• Do not litter the tools.
• Watch your step when walking around on the ma-
chine.
• Remove mud and greases stuck to the shoe sole.
• Never jump down from the machine. When getting on and
off the machine, always face the machine and maintain at least 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.
• You must walk along the access aisle for checking being paved with non-slip pads. Never climb on the en-
gine hood and cover to prevent personal injuries from falling or failing over due to losing your footing.
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT

Machine or work equipment may fall, and it is dangerous that serious personal injury or death may occur. Al-
ways observe the following.
• Make sure the hoists or hydraulic jacks you use are in good condition and strong enough to handle the
weight of the component. Never use hydraulic jacks at places where the machine is damaged, bent, or
twisted. Never use if the element wire of wire rope is frayed, twisted or pinched. Never use bent or distorted
hooks.
• It is extremely dangerous to work under the machine if the
track shoes are lifted off the ground and the machine is
supported only with the work equipment. If any of the con-
trol levers is touched by accident, or there is damage oc-
curring to the hydraulic piping, the work equipment or the
machine will suddenly fall. Never work under the work
equipment or the machine.
• If it is necessary to raise the work equipment or the ma-
chine and then go under it to perform inspection or mainte-
nance, support the work equipment and machine securely ,&
with blocks and stands strong enough to support the
weight of the work equipment and machine.
If the work equipment and machine are not supported, they may come down and it may cause serious per-
sonal injury or death.
• Never use concrete blocks for supports. Concrete blocks may break under even light loads.
USE PROPER TOOLS

Use the tools suited to the task and use them correctly. Using
damaged, deformed, or low quality tools, or making improper
use of the tools may cause serious personal injury or death.
,&
2-29
PRECAUTIONS FOR CHECK AND MAINTENANCE

TURN BATTERY DISCONNECT SWITCH TO OFF POSITION
In the following cases, turn the starting switch to OFF position and check that the system operating lamp is off.
Then set the battery disconnect switch to OFF position and remove the switch key.
If you check and handle battery without turning battery disconnect switch to OFF position, serious personal in-
jury or death by such as an electric shock may occur.
• When storing the machine for a long time (more than 1 month)
• When repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.
PRECAUTIONS FOR WELDING

Welding operations must always be performed by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electric shock when performing welding, so never allow any unqualified
person to perform welding.
HANDLE BATTERY
Before inspecting or handling the battery, turn the key in the starting switch to OFF position and check that the
system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key.
Danger of battery exploding
When the battery is being charged, flammable hydrogen gas is generated and may explode. In addition, the bat-
tery electrolyte includes dilute sulphuric acid. Any mistake in handling may cause serious personal injury, explo-
sion, or fire, so always observe the following.
• Do not use or charge the battery if the battery electrolyte is below LOWER LEVEL mark. This may cause
an explosion. Always perform periodic inspection of the battery electrolyte level, and add purified water
(such as a commercial battery fluid) to UPPER LEVEL mark.
• Do not use a dry wipe to clean the battery. A wet wipe will prevent fire or explosion from static electricity.
• Do not smoke or bring any open flame close to the battery.
• Hydrogen gas is generated when the battery is being
charged, so remove the battery from the machine, take it
to a well-ventilated place, remove the battery caps, then
perform the charging.
• After charging, tighten the battery caps securely.
Danger from dilute sulphuric acid

When the battery is being charged, flammable hydrogen gas is
generated and may explode. In addition, the battery electrolyte
includes dilute sulphuric acid. Any mistake in handling may
cause serious personal injury, explosion, or fire. Always ob-
serve the following.
• When handling the battery, always wear protective eye-
glasses and rubber gloves.
• If battery electrolyte gets into your eyes, immediately wash
your eyes with large amounts of fresh water. After that, get
,&
medical attention immediately.
2-30
• If battery electrolyte gets on your clothes or skin, wash it off immediately with large amounts of water.
Danger of sparks
Sparks may be generated and they can cause a fire. Always observe the following.
• Do not let tools or other metal objects make any contact between the battery cables. Do not leave tools
lying around near the battery.
• When removing the battery cables, turn the starting switch to OFF position and, after checking that the sys-
tem operating lamp goes out, set the battery disconnect switch key to OFF position and pull it out.
When removing the battery cables, remove the ground cable (negative (-) cable) first. When installing, con-
nect the positive (+) cable first, then connect the ground.
• Tighten the battery cable terminals securely.
• Secure the battery firmly in the specified position.
PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may come out or metal particles may be scattered. It is dangerous and may cause
serious personal injury or death. Always observe the following.
• When hitting pins or bucket teeth, broken pieces may be scattered, and it may cause personal injury to the
people in the surrounding area. Always check that there is no one in the surrounding area.
• If hard metal parts such as pins, bucket teeth, cutting
edges, or bearings are hit with a hammer, pieces might be
scattered, and it may cause serious personal injury or
death. Always wear protective eyeglasses and gloves.
• If the pin is hit with strong force, it may come out, and in-
jure people in the surrounding area. Do not allow anyone
to enter the surrounding area.
,&
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT

To prevent burns from boiling water or steam spurting out when
checking or draining the coolant, wait for the coolant to cool
down to a temperature where the radiator cap can be touched
by hand. Then loosen the cap slowly to release the pressure in-
side the radiator, and remove the cap.
PRECAUTIONS FOR HIGH-TEMPERATURE OIL

To prevent burns from hot oil spurting out or from touching
high-temperature parts when checking or draining the oil, wait
for the oil to cool down to a temperature where the cap or plug
can be touched by hand. Then, loosen the cap or plug slowly to
release the internal pressure and remove the cap or plug.
2-31
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS

To prevent burns from touching high-temperature parts, when checking or performing maintenance after stop-
ping engine, check the parts have been cooled down to touch with bare hand before checking or maintenance.
PRECAUTIONS FOR HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. In addition, the fuel piping is also under internal pres-
sure when the engine is running and immediately after the engine is stopped. When performing inspection or
replacement of the piping or hoses, check that the internal pressure in the circuit has been released. If this is not
done, serious personal injury or death may occur. Always observe the following.
• Do not perform inspection or replacement work with the circuit under pressure.
Release the pressure. For details, see “METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIR-
CUIT (4-69)”.
• If there is any leakage from the piping or hoses, the surrounding area may be wet, so check for cracks in
the piping and hoses and for swelling in the hoses.
When performing inspection, wear protective equipment such as protective eyeglasses and leather gloves.
• High-pressure oil leaking from small holes is dangerous
that may penetrate your skin and cause loss of sight if it
contacts your skin or eyes directly. If a jet of high-pressure
oil hit your skin or eyes, and suffer injury, wash the place
with clean water, and consult a doctor immediately for
medical attention.
PRECAUTIONS FOR HIGH-PRESSURE FUEL

While the engine is running, high-pressure is generated in the engine fuel piping. If you try to disassemble the
piping before the internal pressure is released, serious personal injury or death can result. When performing in-
spection or maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the
internal pressure to go down before starting the work.
HANDLE HIGH-PRESSURE HOSES AND PIPING

If oil or fuel leaks from high-pressure hoses or piping, it may cause fire or defective operation. It is dangerous
and may cause serious personal injury or death. If the hose or piping mounts are loose or oil or fuel is found to
be leaking from the mount, stop operations and tighten to the specified torque.
If any damaged or deformed hoses or piping are found, consult your Komatsu distributor.
Replace the hose if any of the following problems are found.
• Damaged hose or deformed hydraulic fitting.
• Frayed or cut covering or exposed reinforcement wire layer.
• Covering swollen in places.
• Twisted or crushed movable portion.
• Foreign material embedded in covering.
2-32
PRECAUTIONS FOR HIGH VOLTAGE

When the engine is running and immediately after it is stopped,
high voltage is generated inside the engine controller and the
engine injector, and there is danger of electric shock. Never
touch the inside of the engine controller or the injector part of
the engine. If it is necessary to touch the inside of the engine
controller or the injector part of the engine, consult your Komat-
su distributor.
PRECAUTIONS FOR NOISE

When performing maintenance of the engine and you are exposed to noise for long periods of time, wear ear
covers or ear plugs while working.
If the noise is too loud, it may cause temporary or permanent hearing problems.
PRECAUTIONS FOR HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK

TENSION
• Grease is pumped into the track tension adjustment sys-
tem under high pressure. If the specified procedure for
maintenance is not followed when making adjustment,
grease drain plug (1) may fly out and cause serious injury
or death or property damage.
• When loosening grease drain plug (1) to loosen the track
tension, never loosen it more than 1 turn. Loosen the
grease drain plug slowly.
• Never put your face, hands, feet, or any other part of your
body close to grease drain plug (1).
DO NOT DISASSEMBLE RECOIL SPRING

Never disassemble the recoil spring assembly.
2-33
The recoil spring assembly has a powerful spring that acts to

reduce the impact on the idler. If it is disassembled by mistake,
the spring may shoot out and cause serious personal injury or
death. If it is necessary to disassemble it, ask your Komatsu
distributor to perform the work.
HANDLE ACCUMULATOR
This machine is equipped with an accumulator. Even after the engine stops, if the work equipment control lever
is operated after stop of the engine in the direction to lower the work equipment, the work equipment goes down
with its own weight.
After stopping the engine, set the parking brake lever and work equipment lock lever to LOCK positions.
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion,
which will lead to serious injury or death. Always observe the following.
• Do not disassemble it.
• Do not bring it near flame or dispose of it in fire.
• Do not make holes in it, weld it, nor use a cutting torch.
• Do not hit or roll it, or subject it to any impact.
• When disposing of the accumulator, the gas must be re-
leased. Ask your Komatsu distributor to perform this work.
PRECAUTIONS FOR COMPRESSED AIR

• When performing cleaning with compressed air, there is a hazard of serious personal injury or death
caused by flying dust or particles.
• When using compressed air to clean the filter element or radiator, wear protective eyeglasses, anti-dust
mask, gloves, and other protective equipment.
MAINTENANCE OF AIR CONDITIONER

If air conditioner refrigerant gets into your eyes, it may cause loss of sight; if it contacts your skin, it may cause
frostbite. Never loosen any parts of the cooling circuit.
CHEMICAL HAZARD
During maintenance or dismantling operations, where there is the risk of contact with hazardous chemical sub-
stances, relevant safety precautions should be taken.
If any doubt exists, contact your Komatsu distributor.
See also “PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS (2-34)” and “MAINTENANCE OF AIR
CONDITIONER (2-34)”
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
2-34
• Always drain the oil from your machine in containers. Nev-

er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.
Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.
METHOD FOR SELECTING WINDOW WASHER FLUID

Use an ethyl alcohol base washer liquid.
Methyl alcohol base washer liquid may irritate your eyes, so do not use it.
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS

• For using the machine safely for a long period, always perform periodic replacement of the defined life parts
that have a particularly close relation to safety, such as hoses and the seat belt.
Replacement of the defined life parts: See “PERIODIC REPLACEMENT OF DEFINED LIFE PARTS”.
• The material of these components naturally changes over time, and repeated use causes deterioration,
wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious personal
injury or death. It is difficult to judge the remaining life of these components from external inspection or the
feeling when operating, so always replace them at the specified interval.
• Replace or repair the defined life parts if any defect is found, even when they have not reached the speci-
fied replacement time.
2-35
PRECAUTIONS FOR DEF SAFETY
PRECAUTIONS FOR DEF

GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
DEF is a colourless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is
used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im-
mediate action:
• If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off
and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or
begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.
PRECAUTIONS FOR ADDING

Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a
fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of DEF tank of the machine, the ammonia vapour may escape. Keep your face away
from the filler port during opening or refilling.
PRECAUTIONS FOR STORING

If the temperature of DEF becomes high, a harmful ammonia gas may be emitted. Completely seal up its con-
tainer for storage. Only open containers in a well-ventilated area.
When storing DEF, avoid direct sunlight. Always use the original container it came in. Do not exchange the con-
tainer of DEF with another one. If DEF is stored in an iron or aluminum container, toxic gas may develop and a
chemical reaction may corrode the container.
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas.
If DEF is spilled, immediately wash and clean the area with water. If spilled DEF is left unattended and the area
is not washed and cleaned, it can cause corrosion to the contaminated area and emit toxic gas.
OTHER PRECAUTIONS
When disposing of DEF, treat it as an industrial waste. The container for DEF is an industrial waste as well. It
should be treated in the same way.
Never use an iron or aluminum container when disposing DEF, because toxic gas may develop and a chemical
reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when handling the
fluid waste of DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
White powder (crystallized urea) may cover the exhaust pipe outlet of aftertreatment devices. When you wipe off
the covered materials, discard the crystallized urea and the used cloth as industrial waste.
Never relocate or modify the exhaust gas aftertreatment devices. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.
2-36
OPERATION
Please read and make sure that you understand the SAFETY section before
reading this section.
3-1
GENERAL VIEW OPERATION
GENERAL VIEW
MACHINE EQUIPMENT NAME
(Sigma dozer)
(Power angle power tilt dozer)
(1) Blade (6) Blade tilt cylinder

(2) Blade lift cylinder (7) Idler
(3) Sprocket (8) Frame
(4) Track (9) Track frame
(5) ROPS cab (10) Blade angle cylinder
3-2
OPERATION GENERAL VIEW
(11) SCR (15) DEF pump

(12) DEF injector (16) Battery disconnect switch
(13) Komatsu Closed Crankcase Ventilation (hereafter (17) System operating lamp
KCCV) ventilator (18) DEF tank
(14) Komatsu Diesel Particulate Filter (hereafter
KDPF)
3-3
GENERAL VIEW OPERATION
CONTROLS AND GAUGES NAMES
(1) Cigarette lighter (9) Starting switch

(2) Parking brake lever (10) Brake pedal
(3) Fuel control dial (11) Decelerator pedal
(4) Joystick (steering, directional and gear shift lever) (12) Work equipment lock lever
(5) Rear lamp switch (13) Blade control lever
(6) Headlamp switch (14) Horn switch
(7) Machine monitor (15) Ripper control lever (if equipped)
(8) Engine shutdown secondary switch
3-4
OPERATION GENERAL VIEW
MACHINE MONITOR EQUIPMENT NAME
AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen
(1) Air conditioner control switch (17) Message display
(2) Buzzer cancel switch (18) Operating mode pilot lamp
(3) Operating mode selector switch (19) Air conditioner pilot lamp
(4) Gear shift mode selector switch (20) Preheating pilot lamp
(5) Customize switch (21) Fan reverse pilot lamp
(6) Reverse travel slow mode switch (22) Reverse travel slow mode pilot lamp
(7) Service meter/clock (23) Hydraulic oil temperature gauge
(8) Power train oil temperature gauge (24) Fuel gauge
(9) ECO gauge or traction force gauge (25) DEF level gauge
(10) Engine coolant temperature gauge (26) DEF level caution lamp
(11) Multi-gauge (27) Fuel consumption gauge
(12) Seat belt caution lamp (28) Gear speed display part
(13) Engine stop pilot lamp (29) Charge level caution lamp
(14) Parking brake pilot lamp (30) Water separator caution lamp
(15) Work equipment lock pilot lamp (31) Engine oil pressure caution lamp
(16) Aftertreatment devices regeneration pilot lamp or (32) Maintenance time caution lamp
Aftertreatment devices regeneration disable pilot (33) Function switches (F1 to F6)
lamp
REMARK
The above figure does not show all of the caution lamp symbols. For details of the caution lamps, see “WARN-
ING DISPLAY (3-13)”.
3-5
EXPLANATION OF COMPONENTS OPERATION
EXPLANATION OF COMPONENTS
The following is an explanation of devices necessary to operate the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operat-
ing the equipment, and the meanings of the displays.
EXPLANATION OF MACHINE MONITOR EQUIPMENT
AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen
(1) Warning display (4) Monitor switch area
(2) Pilot display (5) Guidance icon display
(3) Meter display
REMARK
• For the user menu used for setting various items of the machine on the machine monitor, see “USER
MENU DISPLAY SWITCH (3-52)”.
• If environmental temperature of the machine monitor is high, brightness may be automatically reduced to
protect the liquid crystal.
• Intensity or color of the objects may change because of the automatic adjustment function of the camera.
3-6
OPERATION EXPLANATION OF COMPONENTS
BASIC OPERATION OF MACHINE MONITOR

BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR-
MAL SITUATION
When camera is not set
• When the starting switch is turned to ON position, the opening screen GG is displayed.
• After the opening screen GG is displayed for 2 seconds, the screen switches to the check before starting
screen BB.
• After the check before starting screen BB is displayed for 2 seconds, the screen switches to the preset
(speed range when moving machine off) display screen HH.
• After the preset (starting gear speed) display screen HH is displayed for 2 seconds, the screen switches to
standard screen AA.
REMARK
When the engine is started, the battery voltage may suddenly drop depending on the temperature and the bat-
tery condition. If this happens, the machine monitor may restart, but this does not indicate any abnormality.
3-7
When camera is set
• When the starting switch is turned to ON position, the opening screen GG is displayed.
• After the opening screen GG is displayed for 2 seconds, the screen switches to the camera image FF.
• After the camera image FF is displayed for 2 seconds, the screen switches to the check before starting
screen BB.
• After the check before starting screen BB is displayed for 2 seconds, the screen switches to the preset
(speed range when moving machine off) display screen HH.
• After the preset (starting gear speed) display screen HH is displayed for 2 seconds, the screen switches to
standard screen AA.
REMARK
When the engine is started, the battery voltage may suddenly drop depending on the temperature and the bat-
tery condition. If this happens, the machine monitor may restart, but this does not indicate any abnormality.
BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE

ENGINE SHUTDOWN SECONDARY SWITCH IS ON
While engine shutdown secondary switch (1) is ON (engine is
stopped), when the starting switch is turned to ON position, the
screen shown in the figure is displayed and engine does not
start.
3-8
If engine shutdown secondary switch (1) is turned OFF (nor-

mal), the machine monitor switches to the standard screen,
and you can start the engine with usual starting switch key op-
eration.
For the function and operating method of engine shutdown sec-
ondary switch (1), see “ENGINE SHUTDOWN SECONDARY
SWITCH (3-86)”.
BASIC OPERATION OF MACHINE MONITOR WHEN STOPPING ENGINE IN NOR-

MAL SITUATION
When the starting switch is turned to OFF position, end screen JJ or KK is displayed for 5 seconds, then the
display goes out.
End screen when any message has been re-
ceived
If there is any message from your Komatsu distributor, it is dis-
played on the end screen.
In this case, turn the starting switch to ON position to re-check
the message, and if the message is requesting a response,
make a reply to it.
For the method of displaying and replying KOMTRAX messag-
es, see “MESSAGE DISPLAY (3-79)”.
3-9
BASIC OPERATION OF MACHINE MONITOR WHEN STARTING SWITCH IS ON

WHILE OPERATOR ID INPUT IS SET
• If inputting ID number for operator identification function (with SKIP) is set, the opening screen GG switches
to ID number input screen LL (with SKIP) when the starting switch is turned to ON position.
• If inputting ID number for operator identification function (without SKIP) is set, the opening screen GG
switches to ID number input screen MM (without SKIP) when the starting switch is turned to ON position.
• On the ID number input screen LL (with SKIP) or MM
(without SKIP), input the already registered ID number,
and press switch F6. The screen changes to the Check
Before Starting screen BB. If you input an incorrect ID
number, press switch F5, and clear an input character at a
time.
On the ID number input screen LL (with SKIP), press

switch F1, and the screen changes to the Check Before
Starting screen BB without inputting ID number.
REMARK
• Contact your Komatsu distributor for details of the method
of setting, changing, or canceling the operator identifica-
tion function.
• Depending on the set value of ID holding time, even if in-
putting ID number for operator identification function is set,
the ID number input screen LL (with SKIP) or MM (without
SKIP) may not be displayed while the starting switch is
turned to ON position.
If inputting incorrect ID number for 3 times continuously, you cannot input ID number for 5 minutes. Wait for
more than 5 minutes, try inputting ID number again.
As long as ID number input screen is displayed, the engine cannot be started. If you forget the ID number and
cannot start the engine, ask the person in charge of the machine.
3-10
NOTICE
Since the purpose of the operator identification function is neither security enhancement nor a protec-
tion against theft, it has no antitheft effect. Be careful not to use it for the purpose of security enhance-
ment.
Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or
unauthorized use of ID by a third person.
BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB-

NORMAL SITUATION
• If there is any abnormality when starting the engine, the check before starting screen BB changes to the
maintenance time warning screen CC, warning screen FF-1, or error screen EE.
• After displaying the checks before starting screen BB for 2 seconds, the screen changes to the mainte-
nance time warning screen CC.
• After displaying the maintenance time warning screen CC for 30 seconds, the screen returns to the stand-
ard screen AA.
• After displaying the check before starting screen BB for 2 seconds, the screen changes to the warning
screen FF-1 or error screen EE.
• After displaying warning screen FF-1 for 2 seconds, the screen changes to warning screen FF-2.
3-11
If there is any abnormality currently generated, “!” is displayed

on top of switch F5.
Press switch F5 to check the detail of the current abnormality.

The “Current Abnormality” screen is displayed.
BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE

OPERATING MACHINE
If any abnormality occurs during operation, the standard screen AA changes to the abnormality screen EE.
3-12
If there is any error existing, “!” is displayed on top of switch F5.
Press switch F5 to check the detail of the current abnormality.

The “Current Abnormality” screen is displayed.
WARNING DISPLAY
NOTICE
Appearance of any of action levels “L01” to “L04” on the machine monitor indicates presence of an ab-
normality the machine.
Take appropriate actions following the list of action level displays and remedies.
The caution lamp that lights up in red when an action level is displayed warns operator to stop the ma-
chine urgently, stop or pause the current operation.
If no action is taken, the machine can be seriously affected. Take necessary actions immediately.
3-13
(1) Action level display (6) Hydraulic oil temperature caution lamp
(2) Caution lamp (7) DEF level caution lamp
(3) Caution lamp (8) Fuel level caution lamp
(4) Engine coolant temperature caution lamp (9) Power train oil temperature caution lamp
(5) Engine speed caution lamp (*) (10) Caution lamp
(*): Displayed items change according to setting of the multi-gauge. For details of the multi-gauge, see “MULTI
GAUGE (3-35)”.
Standard screen
When 1 type of caution is generated, it is displayed on caution lamp (2).
When 2 types of caution are generated, they are displayed on caution lamps (2) and (3).
When 3 types or more of caution are generated, they are displayed on caution lamps (2) and (3) alternately at
intervals of 2 seconds.
Camera image display screen
The current cautions are indicated by flashing of caution lamp (10).
When 2 or more cautions are generated, they are sequentially displayed starting from the leftmost side of the
screen.
3-14
ACTION LEVEL DISPLAY

Action level display indicates the degree of urgency of the ab-
normality currently generated on the machine by “L01” to “L04”.
The larger the number in the table is, the more serious effects
the abnormality may have on the machine if it is left with no ac-
tion.
If the machine monitor indicates an action level, check the
message of the action level display.
By pressing switch F5 on the standard screen while the action
level is displayed, the list of the Current Abnormality is dis-
played.
For the display method of failures, see “CURRENT ABNOR-
MALITY DISPLAY SWITCH (3-18)”.
Take appropriate actions according to the message of the ac-
tion level display.
List of action level display and required actions

Degree
Action lev-
of ur- Buzzer Caution lamp Required action
el
gency
Sounds contin- Lights up in Stop the machine immediately and ask your Komatsu distrib-
L04
uously red utor for inspection and maintenance.
High Stop the operation and move the machine to a safe place,
Sounds inter- Lights up in
↑ L03 then ask your Komatsu distributor for inspection and mainte-
mittently red
nance.
│
│ Stop the operation and run the engine at medium speed with
Sounds inter- Lights up in no load or stop it.
│ L02
mittently red If the condition is not improved, ask your Komatsu distributor
│
for inspection and maintenance.
│
Some functions may be restricted from use, but the machine
↓ can operate. When you finish the operation, always perform
Low Does not Lights up in the inspection and maintenance.
L01
sound yellow
Ask your Komatsu distributor for inspection and maintenance
as needed.
3-15
CAUTION LAMP LIST

NOTICE
• These caution lamps do not guarantee the condition of the machine.
Do not simply rely on the caution lamp when performing checks before starting (start-up inspec-
tion). Always get off the machine and check each item directly.
• When the caution lamp is displayed in red, if no action is taken, the machine can be seriously affect-
ed.
Take the action immediately.
• The engine output or engine speed is limited and the machine operation speed may become slow,
depending on the contents of the warning.
• When the engine output or engine speed is limited by the warning of action level “L03” or higher,
the limit may not be canceled even if the warning is canceled.
In this case, stop the machine and lower the engine speed to low idle with the fuel control dial or the
decelerator pedal. The engine output or engine speed limitation is reset.
Caution lamps and display colors

Display color/Machine condition (Action level)
Symbol Type of caution lamp
Red Yellow Blue White
High temper-
Engine coolant temperature cau- ature - Normal -
tion lamp
(L02)
High temper-
Power train oil temperature cau- ature - Normal -
tion lamp
(L02)
High temper-
Hydraulic oil temperature caution ature - Normal -
lamp
(L02)
Fuel level caution lamp Low level - Normal -
Abnormal Abnormal
System caution lamp - -
(L04, L03) (L01)
Work equipment system caution Abnormal Abnormal

- -
lamp (L04, L03) (L01)
Abnormal Abnormal
Steering system caution lamp - -
(L04, L03) (L01)
Abnormal Abnormal
Brake system caution lamp - -
(L04, L03) (L01)
Transmission system caution Abnormal Abnormal

- -
lamp (L04, L03) (L01)
3-16

Abnormal Abnormal
KDPF system caution lamp - -
(L04, L03) (L01)
KDPF soot accumulation caution Abnormal Accumulated

- -
lamp (L03) (L01)
Abnormal Sensing is
DEF level caution lamp - Normal
(L04, L03) disabled
Abnormal Abnormal
DEF system caution lamp - -
(L04, L03) (L01)
Engine stop-
DEF system high temperature ped at high
- temperature - -
stop caution lamp
(L01)
Abnormal Abnormal
Engine system caution lamp - -
(L04, L03) (L01)
Parking brake system caution Abnormal Abnormal

- -
lamp (L04, L03) (L01)
Abnormal Abnormal
Fan control system caution lamp - -
(L04, L03) (L01)
Low oil pres-

Engine oil pressure caution lamp sure - - -
(L03)
Overspeed
Engine overrun caution lamp - - -
(L02)
Abnormal
Charge level caution lamp - - -
(L03)
Water separator caution lamp Abnormal - - -
Clogged
Air cleaner clogging caution lamp - - -
(L01)
3-17

Air conditioner system caution Abnormal

- - -
lamp (L01)
Due time is
Maintenance time caution lamp Notice - -
over
Seat belt is
Seat belt caution lamp - - -
not fastened
For the meaning of each caution lamp and the action to take for it, see the section of each caution lamp.
CURRENT ABNORMALITY DISPLAY SWITCH

If there is any abnormality currently generated, “!” is displayed
on top of switch F5.
While “!” is displayed, press switch F5 to shift the monitor dis-
play screen to the “Current Abnormality” screen.
Take appropriate remedies according to the displayed mes-
sage.
Operation on the “Current Abnormality” screen

On the “Current Abnormality” screen, you can perform the fol-
lowing operations with switches F1, F2 and F5.
3-18
F1: Displays the next page. When on the last page, it displays
the first page.
F2: Displays the previous page. When on the first page, it dis-
plays the last page.
F5: Returns the screen to the standard screen.
ENGINE COOLANT TEMPERATURE CAUTION LAMP

Engine coolant temperature caution lamp warns about states
caused by engine coolant temperature.
When abnormal
The caution lamp lights up in red and indicates action level
“L02”.
The engine coolant temperature is abnormally high.
While this lamp is lit, the overheat prevention system is auto-
matically actuated and the engine speed drops.
Stop operations and run the engine at low idle until the caution
lamp changes to the normal display color (blue) at a proper
temperature.
When temperature is proper
The caution lamp lights up in blue.
POWER TRAIN OIL TEMPERATURE CAUTION LAMP

The power train oil temperature caution lamp warns about the
power train oil temperature.
When abnormal
“L02”.
The power train oil temperature has risen abnormally high.
While this lamp is lit, the overheat prevention system is auto-
matically actuated and the engine speed drops.
Stop operations and run the engine at low idle or stop it until
the caution lamp changes to the normal display color (blue) at
an appropriate temperature.
3-19
HYDRAULIC OIL TEMPERATURE CAUTION LAMP

The hydraulic oil temperature caution lamp warns about states
of hydraulic oil temperature.
When abnormal
“L02”.
The hydraulic oil temperature is abnormally high.
Stop operations and stop the engine or run it at low idle until
the caution lamp changes to the normal display color (blue) at
an appropriate temperature.
FUEL LEVEL CAUTION LAMP

The fuel level caution lamp warns about low remaining fuel lev-
el.
When fuel level is low
The caution lamp lights up in red.
The remaining fuel amount is approximately 102 ℓ or less.
Add fuel as soon as possible.
When normal
SYSTEM CAUTION LAMP

The system caution lamp warns about abnormality in the ma-
chine system, including the sensors.
When action level “L04” is displayed
The caution lamp lights up in red and the alarm buzzer sounds
continuously.
Stop the machine immediately and ask your Komatsu distribu-
tor for inspection and maintenance.
intermittently.
Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and
maintenance.
The caution lamp lights up in yellow.
Some functions may be restricted for use, but the machine can operate.
When you finish the operation, always perform the inspection and maintenance.
Ask your Komatsu distributor for inspection and maintenance as needed.
3-20
WORK EQUIPMENT SYSTEM CAUTION LAMP

The work equipment system caution lamp warns about abnor-
mality in the work equipment system.
continuously.
intermittently.
maintenance.
When you finish the operation, always have the inspection and maintenance performed.
As needed, ask your Komatsu distributor for inspection and maintenance.
STEERING SYSTEM CAUTION LAMP

The steering system caution lamp warns about abnormality in
the steering system.
continuously.
intermittently.
Stop the operation, move the machine to a safe place, and then ask your Komatsu distributor for the inspection
and maintenance.
BRAKE SYSTEM CAUTION LAMP

The brake system caution lamp warns about abnormality in the
brake system.
continuously.
3-21

The caution lamp lights up in red and the buzzer sounds intermittently.
Stop the operation, move the machine to a safe place, and have the inspection and maintenance performed.
For the inspection and maintenance, ask your Komatsu distributor.
TRANSMISSION SYSTEM CAUTION LAMP

The transmission system caution lamp warns about abnormali-
ty in the transmission system.
continuously.
intermittently.
Stop the operation, move the machine to a safe place, and have the inspection and maintenance performed.
For the inspection and maintenance, ask your Komatsu distributor.
KDPF SYSTEM CAUTION LAMP

The KDPF system caution lamp warns about abnormality in the
KDPF system.
continuously.
intermittently.
maintenance.
3-22
REMARK
For details of KDPF, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-104)”.
KDPF SOOT ACCUMULATION CAUTION LAMP

The KDPF soot accumulation caution lamp warns that soot is
accumulated in KDPF or the filtering function of KDPF has low-
ered abnormally.
To cancel the alarm, perform the manual stationary regenera-
tion of KDPF.
When abnormal
“L03”.
The alarm buzzer sounds intermittently.
Large accumulation of soot in KDPF or a system failure such
as lowering of the filtering function of KDPF occurred.
Urgent remedy is required.
Move the machine to a safe place immediately and perform the manual stationary regeneration.
The manual stationary regeneration may start automatically to protect KDPF system.
When soot is accumulated
The caution lamp lights up in yellow and indicates action level “L01”.
Much soot is accumulated in KDPF, however, the operation can be performed.
After the operation is finished, move the machine to a safe place and perform manual stationary regeneration.
REMARK
For details of the manual stationary regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF)
(3-104)”.
DEF LEVEL CAUTION LAMP

DEF level caution lamp alerts when DEF tank level becomes
low.
Whenever the caution lamp lights up in red, immediately add
DEF.
Fault conditions that result in activation of the Inducement strat-
egy for engine derates to prompt to maintain or repair the emis-
sion control system.
When Lightning in red,
With Action level “L04”, DEF tank level is too low. Inducement
status is “Severe Inducement”. Engine power is under heavy
deration.
With Action level “L03”, DEF tank level is low. Inducement status is “Low level Inducement”. Engine power is
under deration.
With No Action level display. DEF tank level is lower. Inducement status is “Continuous Warning”. Need to add
DEF immediately to avoid advancing to the next Inducement status.
With No Action level display. DEF tank level is becomes low. Warning starts. Inducement status is “Warning”.
Need to add DEF immediately.
When Lightning in white
When fluctuation of DEF tank level is large, frozen, or not limited to, tank level sensing is not performed correct-
ly.
When DEF is added after engine starting switch turn to OFF.
When DEF tank level sensor is defective.
3-23
REMARK
For more information about the Inducement strategy, and Inducement status concerning engine power deration,
see “HANDLE UREA SCR SYSTEM WARNING (3-114)”.
DEF SYSTEM CAUTION LAMP

DEF system caution lamp alerts when abnormality in the sys-
tem are detected.
Whenever the caution lamp lights up in yellow or in red, take
necessary actions by instructions.
Fault conditions that result in activation of the Inducement strat-
egy for engine derates to prompt to maintain or repair the emis-
sion control system.
Lighting in red
With Action level “L04”, Inducement status is “Severe Induce-
ment”. Engine power is under heavy deration.
With Action level “L03”, Inducement status is “Low level Inducement”. Engine power is under deration.
Lighting in yellow
With Action level “L01”, Inducement status is “ Warning” or “Continuous Warning”.
When “Continuous Warning”, If no maintenance, advancing to the next Inducement status. Engine power will be
derated.
REMARK
For more information about the Inducement strategy, and Inducement status concerning engine power deration,
see “HANDLE UREA SCR SYSTEM WARNING (3-114)”.
DEF SYSTEM HIGH TEMPERATURE STOP CAUTION LAMP

DEF system high temperature stop caution lamp alerts when
the times of engine is shut down under the condition of high de-
gree temperature of DEF system exceeds the defined number
of times.
Whenever the caution lamp lights up in yellow, it is necessary
to ask your Komatsu distributor to go off this caution lamp.
When stopping the engine, stop it after running it at low idle for
approximately 5 minutes. For details, see “METHOD FOR
STOPPING ENGINE (3-167)”.
When stopping the engine during aftertreatment devices regen-
eration, stop the regeneration first according to “PROCEDURE
FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING (3-110)”, then stop the engine after
running it at low idle for approximately 5 minutes.
PARKING BRAKE SYSTEM CAUTION LAMP

The parking brake system caution lamp warns about abnormal-
ity in the parking brake system.
continuously.
intermittently.
3-24
Stop the work, move the machine to a safe place, and then ask your Komatsu distributor for inspection and
maintenance.
When you finish the operation, always perform the inspection and maintenance.
ENGINE SYSTEM CAUTION LAMP

k WARNING
If the operation is continued while the red caution lamp is lit, accumulation and combustion of the soot
in KDPF are accelerated, and consequently the temperature of KDPF and exhaust gas can increase
high. Stop the engine immediately.
The engine system caution lamp warns about abnormality in

the engine system.
continuously.
intermittently.
maintenance.
FAN CONTROL SYSTEM CAUTION LAMP

The fan control system caution lamp warns about abnormality
in the fan control system.
continuously.
intermittently.
maintenance.
3-25
ENGINE OIL PRESSURE CAUTION LAMP

Engine oil pressure caution lamp warns about abnormality of
engine lubricating oil pressure.
When oil pressure is low
“L03”.
Stop the operation and move the machine to a safe place, then
ask your Komatsu distributor for inspection and maintenance.
ENGINE OVERRUN CAUTION LAMP

The engine overrun caution lamp lights up when engine over-
run occurs.
Since overrun can damage the engine and hydraulic compo-
nents, stop the work immediately and operate at low travel
speed until the overrun caution lamp goes out.
CHARGE LEVEL CAUTION LAMP

Charge level caution lamp warns about abnormality in the
charging system while the engine is running.
When abnormal
“L03”.
Charging is not be performed normally while the engine is run-
ning.
Stop the engine and check the alternator belt and air condition-
er compressor belt for damage, then ask your Komatsu distrib-
utor for inspection and maintenance.
WATER SEPARATOR CAUTION LAMP

The water separator caution lamp warns that water is accumu-
lated in the water separator.
When abnormal
Water is accumulated in the water separator.
Stop the engine and drain water from the water separator.
For detail, see “METHOD FOR CHECKING WATER SEPARA-
TOR, DRAINING WATER AND SEDIMENT (3-134)”.
3-26
REMARK
The water separator forms one unit with the fuel prefilter.
The water separator is installed at the bottom of the fuel prefilter as detachable condition.
AIR CLEANER CLOGGING CAUTION LAMP

Air cleaner clogging caution lamp warns about clogging of the
air cleaner.
When clogged
The caution lamp lights up in yellow and indicates action level
“L01”.
The air cleaner is clogged.
Stop the engine and check and clean the air cleaner.
For detail, see “METHOD FOR CHECKING, CLEANING AND
REPLACING AIR CLEANER”.
AIR CONDITIONER SYSTEM CAUTION LAMP

Air conditioner system caution lamp warns about abnormality in
air conditioner system.
When abnormal
The caution lamp lights up in yellow and indicates action level
“L01”.
The air conditioner system has abnormality.
Ask your Komatsu distributor for inspection and maintenance
as soon as possible.
MAINTENANCE TIME CAUTION LAMP

Maintenance time caution lamp displays notices and alarms
concerning maintenance time.
This lamp lights up when the starting switch is turned to ON po-
sition. It goes out after 30 seconds and the display changes to
the standard screen.
When the due time is over
The maintenance due time is over.
If no action is taken, the machine performance will become
worse and the machine life will be shortened.
Perform necessary maintenance as soon as possible.
When giving the notice of the due time
The maintenance due time is approaching.
Prepare necessary parts for the maintenance.
3-27
REMARK
• Check maintenance items on the “Maintenance” screen by
pressing switch F6 on the maintenance time warning
screen shown in the drawing or on the standard screen.
• The lighting time of maintenance due time notice (yellow)
has been initially set to 30 hours, but it can be changed.
To change the setting, ask your Komatsu distributor.
• For operations on the “Maintenance” screen, see “MAIN-
TENANCE SCREEN SETTING (3-67)”.
SEATBELT CAUTION LAMP

The seat belt caution lamp lights up in red when the seat belt is
not fastened. It goes out when the seat belt is fastened.
For fastening the seat belt, see “METHOD FOR FASTENING
AND UNFASTENING SEAT BELT”.
PILOT DISPLAY AND METER DISPLAY
Pilot display
(1) Engine stop pilot lamp (2) Parking brake pilot lamp
3-28
(3) Work equipment lock pilot lamp (9) Preheating pilot lamp
(4) Aftertreatment devices regeneration pilot lamp (10) Fan reverse rotation pilot lamp
(5) Aftertreatment devices regeneration disable pilot (11) Reverse travel slow mode pilot lamp
lamp (12) Guidance display
(6) Message display (13) Gear speed display
(7) Operating mode display
(8) Air conditioner pilot lamp
Meter display
(14) Service meter/clock (19) Hydraulic oil temperature gauge
(15) Power train oil temperature gauge (20) DEF level gauge
(16) ECO gauge or drawbar pull gauge (21) Fuel gauge
(17) Engine coolant temperature gauge (22) Fuel consumption gauge
(18) Multi-gauge
PILOT DISPLAY
The pilot display at the top of the screen consists of the pilot lamps to check the actuation of each function.
When the starting switch is turned on and the display items are functioning, the pilot lamps light up.
PREHEATING PILOT LAMP

The preheating pilot lamp is displayed while the engine is pre-
heated before started at temperature below -3 °C.
When the temperature is low (in cold weather) and the auto-
matic preheating function operates, the preheating pilot lamp
lights up. When the preheating is completed, it goes out.
Automatic preheating is for a maximum of approximately 45
seconds.
FAN REVERSE ROTATION PILOT LAMP

The fan reverse rotation pilot lamp lights up while the fan is ro-
tating in reverse.
For the reverse rotation of the fan, see “MACHINE SETTINGS
(3-63)”.
3-29
AIR CONDITIONER PILOT LAMP

The air conditioner pilot lamp shows the operating state of the
air conditioner.
Pilot lamp lights up: Air conditioner ON
Pilot lamp goes out: Air conditioner OFF
MESSAGE DISPLAY
The User Message is displayed when there is a message from
Komatsu.
To read the message, see “MESSAGE DISPLAY (3-79)”.
Lights up in green (A): There is unread message.
Lights up in blue (B): There is any read message to which no
reply is made.
OFF: No messages
OPERATING MODE DISPLAY

The currently set operating mode is displayed on the operating
mode display.
The display of the operating mode is as follows.
(P): For heavy-duty operations
Lights up when the mode is set to power mode.
(E): For operations with emphasis on fuel consumption
Lights up when the mode is set to economy mode.
The operating mode changes each time the operating mode
selector switch is pressed.
ENGINE STOP PILOT LAMP

The engine stop pilot lamp is displayed while the engine is
stopped. It goes out when the engine is started.
3-30
AFTERTREATMENT DEVICES REGENERATION PILOT LAMP

k CAUTION
• Exhaust gas temperature may increase higher than the previous models during the aftertreatment
devices regeneration. Stay away from the exhaust pipe outlet to prevent yourself from getting burnt.
Also, keep combustible materials away from the exhaust pipe outlet to prevent a fire.
• When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to
the regeneration disable to prevent fire hazards due to highly heated exhaust gas during the after-
treatment devices regeneration. For details of the setting method, see “HANDLE Komatsu Diesel
Particulate Filter (KDPF) (3-104)”.
The aftertreatment devices regeneration pilot lamp lights up

during regeneration of the exhaust gas aftertreatment devices.
It goes out when the regeneration is completed.
AFTERTREATMENT DEVICES REGENERATION DISABLE PILOT LAMP

Aftertreatment devices regeneration disable pilot lamp lights up
when the aftertreatment devices are set not to be regenerated.
REMARK
Even if the aftertreatment devices regeneration is disabled,
when the manual stationary regeneration is necessary, KDPF
soot accumulation caution lamp lights up. If KDPF soot accu-
mulation caution lamp lights up, cancel regeneration disable
setting and perform manual stationary regeneration.
For the procedures of cancellation of the regeneration disable
setting, and setting of manual stationary regeneration, see
“HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-104)”.
WORK EQUIPMENT LOCK PILOT LAMP

The work equipment lock pilot lamp lights up when the work
equipment lock lever is in LOCK position.
It goes out when the work equipment lock lever is set in FREE
position.
If it is required to set the work equipment lock lever in LOCK
position, the work equipment lock pilot lamp flashes.
3-31
PARKING BRAKE PILOT LAMP

The parking brake pilot lamp lights up when the parking brake
lever is in LOCK position.
It goes out when the parking brake lever is set to FREE posi-
tion.
When the parking brake lever needs to be set to LOCK posi-
tion, the parking brake pilot lamp flashes.
REVERSE SLOW MODE PILOT LAMP

The reverse slow mode pilot lamp lights up when the reverse
slow mode is set.
If the reverse slow mode is set, it is possible to throttle down
the engine speed automatically to decrease the reverse speed.
The reverse slow mode is set and canceled with the reverse
slow mode switch.
GUIDANCE DISPLAY
The guidance for energy saving operation to reduce the fuel
consumption may be displayed during operation.
The details of the guidance are as follows:
Idling stop guidance

If no operation is performed for more than 5 minutes, and the
engine is idling, the idling stop message is displayed on the
machine monitor. When waiting for work or taking short break,
stop the engine to reduce unnecessary fuel consumption.
• The idling stop guidance goes out if any lever is operated
again or switch F5 is pressed.
• For the auto idle stop function, see “AUTO IDLE STOP
TIMER SETTING (3-66)”.
3-32
Guidance to avoid hydraulic relief

If the hydraulic oil is kept relieved for more than 10 seconds
during operation, the hydraulic relief deterrence message is
displayed on the machine monitor.
The hydraulic relief deterrence message goes out 5 seconds
later or when switch F5 is pressed.
E mode recommendation guidance

If light-load work is continued for more than 10 minutes in P
mode, E mode recommendation message is displayed on the
machine monitor. When working on light load, set the operating
mode to E to reduce unnecessary fuel consumption.
E mode recommendation guidance goes out more than 5 sec-
onds after or when switch F5 is pressed.
Overload prevention guidance

If the machine is overloaded during work, overload prevention
message is displayed on the machine monitor.
Fuel consumption can be reduced by avoiding shoe slip or op-
erating the machine in the green zone of ECO gauge.
Overload prevention guidance goes out more than 5 seconds
later or when switch F5 is pressed.
Automatic gear shift mode recommendation guidance

If you continue working in the manual shift mode for more than
1 hour, the automatic shift recommendation message is dis-
played on the machine monitor.
Since proper speed ranges are selected during the ordinary
dozing work in the automatic shift mode, fuel consumption is
reduced.
The automatic shift recommendation guidance goes out in 5
seconds or when switch F5 is pressed.
DEF level low error guidance

At 15 seconds after the starting switch is turned to ON position and the standard screen is displayed, if the oper-
able time estimated from current DEF level and the latest average DEF consumption is shorter than 8 hours,
DEF Level Low Error guidance is displayed.
3-33
When the time until engine output power limitation starts is 1 to 8 hours
“Approx. * hours remaining to DEF refill caution.” is displayed.
When the time until engine output power limitation starts is less than 1 hour
“DEF refill caution will appear soon.” is displayed.
DEF Level Low Error guidance goes out in more than 15 seconds or when switch F5 is pressed.
For the remaining amount of DEF, see “DEF LEVEL GAUGE (3-39)”.
Engine stop operation during the aftertreatment devices regeneration guidance
Immediately after starting aftertreatment devices regeneration, the information about engine stop operation dur-
ing the aftertreatment devices regeneration is displayed on the machine monitor.
When stopping the engine during aftertreatment devices regen-
eration, stop the regeneration first according to “PROCEDURE
FOR AFTERTREATMENT DEVICES REGENERATION DISA-
BLE SETTING (3-110)”, then stop the engine after running it at
low idle for approximately 5 minutes.
The guidance about engine stop operation during the aftertreat-
ment devices regeneration goes out 10 seconds later or when
switch F5 is pressed.
3-34
SPEED RANGE DISPLAY

The gear speed display section indicates the following informa-
tion.
The travel gear speed of the machine (“F1” for FORWARD 1st,
“R2” for REVERSE 2nd) is displayed in top left area (a).
The gear shift mode is displayed in top right area (b).
The preset mode is displayed in bottom area (c).
In addition, when the automatic gear shift mode is selected, the
“AUTO” mark is displayed, and when the manual gear shift
mode is selected, the “MAN” mark is displayed in the bottom
left area (d).
For gear shift operation of the machine, see “SHIFT GEARS
(3-171)”.
METER DISPLAY
MULTI GAUGE
The multi gauge can display various items. As an example, dis-
play of the engine tachometer is explained below.
If the indicator is in green range during operations, it is normal.
When the indicator goes beyond (A) of red range during opera-
tions, the engine speed is too high. Decrease the travel speed
in this case.
(A) to (B): Red range
(A) to (C): Green range
For other items displayed by the multi gauge, see “METHOD
FOR USING MULTI GAUGE (3-50)”.
ENGINE COOLANT TEMPERATURE GAUGE

Engine coolant temperature gauge shows the engine coolant
temperature.
When the indicator goes beyond (A) of red range during opera-
tions, the overheat prevention system is actuated.
(C) to (D): White range
The overheat prevention system is actuated as follows.
Red range (A) position: Engine coolant temperature caution
lamp (E) shows abnormality display.
Red range (B) position: Engine speed changes to a medium speed, engine coolant temperature caution lamp
(E) shows abnormality display, and alarm buzzer sounds at the same time.
The overheat prevention system continues to operate until the indicator enters the green range.
3-35
When the engine is started, if the indicator is in position (D), perform the warm-up operation. For details, see
“METHOD FOR ENGINE WARM-UP OPERATION (3-165)”.
Display (H) when temperature is proper: Back ground (K) of en-
gine coolant temperature caution lamp lights up in blue.
Display (J) when temperature is abnormal: Back ground (K) of
engine coolant temperature caution lamp lights up in red.
POWER TRAIN OIL TEMPERATURE GAUGE

The power train oil temperature gauge indicates the power train
oil temperature.
If the indicator goes beyond (A) of red range during operations,
the overheat prevention system operates.
The overheat prevention system operates as follows.
Red range (A) position: Power train oil temperature caution
lamp (E) shows abnormality display.
Red range (B) position: Engine speed changes to medium speed, power train oil temperature caution lamp (E)
shows abnormality display, and alarm buzzer sounds at the same time.
NOTICE
If the power train oil temperature gauge tends to enter the red range, shift down one speed range to re-
duce the load on the power train during operations.
Normal temperature display (H): Background (K) of power train
oil temperature caution lamp lights up in blue.
Abnormal display (J): Background (K) of power train oil temper-
ature caution lamp lights up in red.
3-36
HYDRAULIC OIL TEMPERATURE GAUGE

Hydraulic oil temperature gauge shows the hydraulic oil tem-
perature.
If the indicator goes beyond red range (A) during operations,
the overheat prevention system operates.
The overheat prevention system operates as follows.

Red range (A) position: Hydraulic oil temperature caution lamp (E) shows abnormality display.
Red range (B) position: Engine speed changes to a middle level, hydraulic oil temperature caution lamp (E)
shows abnormality display, and alarm buzzer sounds at the same time.
NOTICE
When the indicator comes close to red range (A) during operation, run the engine at low idle or stop it,
and wait for the hydraulic oil temperature to drop.
Display (H) when temperature is proper: Background (K) of hy-
draulic oil temperature caution lamp lights up in blue.
Display (J) when abnormal: Background (K) of hydraulic oil
temperature caution lamp lights up in red.
FUEL GAUGE
Fuel gauge shows the amount of fuel in the fuel tank.
The indicator should be in the green range during operations.
When the indicator comes close to (A) of the red range during
operation, check and add fuel as necessary.
REMARK
When the indicator is in red ranges (A) to (B), fuel level caution
lamp (D) lights up in red.
The correct fuel level may not be displayed for a short time after the starting switch is turned to ON position, but
this is not abnormal.
3-37
SERVICE METER/CLOCK
The service meter/clock shows the total hours of operation of
the machine or the present time.
When the engine is running, the service meter advances even
when the machine is not moving. The service meter advances
0.1 every 6 operation minutes, regardless of the engine speed.
By pressing switch F4 on the standard screen, you can switch
the clock display and service meter display.
REMARK
• If the battery is disconnected for a long period for storage
etc., the time information may be lost.
• 12-hour or 24-hour system is available for clock display.
• For details of setting and correction of time, see “CLOCK
ADJUSTMENT (3-72)”.
Service meter display
Clock display (12-hour display)
Clock display (24-hour display)
3-38
ECO GAUGE / DRAWBAR PULL GAUGE

The ECO gauge/ drawbar pull gauge displays ECO gauge (in-
stantaneous fuel consumption) (C) or drawbar pull gauge (work
load) (D).
The instantaneous fuel consumption means the fuel consump-
tion rate at each moment, which varies with the work load and
engine speed.
When the gauge is in green range (A), the instantaneous fuel
consumption is at a good to medium level.
When the gauge is in yellow range (B), the instantaneous fuel
consumption is at a bad level.
REMARK
Although there is no abnormality on the machine when the gauge enters the yellow range, for the conservation
of global environment reduce the engine output to a point where there is no adverse effect on the operation.
Perform energy saving operations within the green range. Travel less frequently. It also helps energy saving op-
erations. Consider the best way of operation for energy saving.
FUEL CONSUMPTION GAUGE

Fuel consumption gauge shows the average fuel consumption
of the machine.
(A): Shows the average fuel consumption of a day (from 0:00
a.m. of the day to 0:00 a.m. of the next day).
(B): Shows the split fuel consumption under measurement.
(C): Shows the split fuel consumption while measurement is
stopped.
REMARK
Display on the fuel consumption gauge can be switched be-
tween the average fuel consumption per day and the average
fuel consumption during a selected period (split fuel consump-
tion).
DEF LEVEL GAUGE

DEF level gauge indicates the remaining level of DEF.
If the indicator comes close to (A) of red range during opera-
tion, check and add DEF.
When the indicator is in red range from (A) to (B), DEF level
caution lamp (1) lights up in red.
If DEF level further decreases after the lamp lights up in red,
the engine output power and engine speed are limited. For de-
tail, see “HANDLE UREA SCR SYSTEM WARNING (3-114)”.
When remaining level of DEF cannot be detected, DEF level caution lamp (1) lights up in white.
3-39
REMARK
• Immediately after turning the starting switch to ON position and during the engine is running, DEF level cau-
tion lamp (1) lights up in white. However, this does not indicate abnormality.
• In cold weather, DEF level cannot be detected and DEF level caution lamp (1) lights up in white for approxi-
mately 1 hour. However, this does not indicate abnormality.
• Even if DEF level caution lamp (1) is not lit in white, it may take a long time for DEF level gauge to display
the correct position.
Note that the following cases are not abnormal:
• When DEF is added while the starting switch is kept at ON position.
• When the starting switch is turned to ON position immediately after adding DEF (within approximately
30 seconds).
Before adding DEF, turn the starting switch to OFF position. Wait for a while after adding, then turn the
starting switch to ON position.
MONITOR SWITCHES
(1) Function switch (5) Gear shift mode selector switch

(2) Air conditioner switch (6) Customize switch
(3) Buzzer cancel switch (7) Reverse travel slow mode switch
(4) Operating mode selector switch
FUNCTION SWITCHES AND GUIDANCE ICONS

• Function switches (1) at the bottom of the monitor display
consist of 6 switches (F1 to F6). The function of each
switch differs according to the content of each screen.
• The function of switches (1) on each screen can be con-
firmed by guidance icons (2) displayed on top of the
switch.
• While guidance icon (2) is not displayed, switch (1) does
not function even if it is pressed.
• Even if guidance icon (2) is pressed, it does not function.
Press function switch (1) directly under guidance icon (2)
to operate the function.
When the monitor display shows the standard screen, the types of guidance icons and functions of function
switches are as follows:
For the details of each function, see the detailed explanation of each item.
3-40
(A) Switch F2: Multi-gauge selector switch
(B) Switch F3: Camera image selector switch.

(C) Switch F4: Service meter / clock display selector switch
(D) Switch F5: Current Abnormality display switch

(Only while caution lamp is lit)
(E) Switch F5: Energy saving (ECO) guidance erase switch
(While ECO guidance is displayed)
(F) Switch F6: User menu display switch
Guidance icons and their functions differ with the contents of the displayed screen, but representative guidance
icons frequently used and their functions are as follows:
(G) Switch F1 or F3: Moves to the left item. (When on the left
end, it moves to the right end.)
(H) Switch F2 or F4: Moves to the right item. (When on the
right end, it moves to the left end.)
3-41
(I) Switch F3: Moves to the item below (forward). (When on the
last line, it moves to the first line on the next page.)
(J) Switch F4: Moves to the item above (backward). (When on
the first line, it moves to the last line on the previous page.)
(K) Switch F5: To cancel any change and return to the previous
screen.
(L) Switch F6: To decide any selection and change contents
and to advance to the next screen.
REMARK
• Even if guidance icons are of the same shape, their display positions and corresponding function switches
may differ according to screens to be displayed.
• For the guidance icons and their functions not explained above, see the pages where the control methods
of respective screens are explained.
BUZZER CANCEL SWITCH

Buzzer cancel switch is used to stop the alarm buzzer for the warning item where there is an abnormality.
The buzzer cannot be stopped according to the content of the
warning.
AIR CONDITIONER SWITCH

The air conditioner switch consists of 9 switches.
For explanation of each switch, see “HANDLE AIR CONDI-
TIONER (3-202)”.
3-42
OPERATING MODE SELECTOR SWITCH

The operating mode selector switch is used for switching the
operating mode of the engine.
Normally, it is possible to perform all operations in E mode, and
this mode reduces fuel consumption.
Compared with E mode, P mode has more power, but the fuel
consumption increases.
When the starting switch is turned to ON position, the mode
used for the previous operation is selected by default.
The selected mode is displayed at the top of the screen.
CUSTOMIZE SWITCH
k CAUTION
To ensure safety, always stop the machine before operating the customize mode.
Press the customize switch, and the “Mode Select” screen is

displayed.
On the “Mode Select” screen, you can set and save the follow-
ing items as desired.
Item Contents of setting
Operating Mode Power/Economy
Gear Shift Mode Manual gear shift mode/ Automatic gear shift
mode
Reverse Slow ON/OFF
Auto Shift Down* ON/OFF
*: When manual shift mode is selected

Setting and saving each item
1. Press switch F3 or F4 on the “Mode Select” screen to set
the yellow cursor to the target item of setting change, and
then press switch F6.
The setting change screen for the selected item is dis-
played.
2. Press switch F3 or F4 to move the yellow cursor to a set-

ting to change, and press switch F6.
(The figure shows an example of the setting change
screen when the “Operating Mode” is selected.)
3-43
3. After the setting change of each item is complete, press

switch F2.
The memory saving screen is displayed.
4. Check the setting of each item (on the left of the screen).
5. Press switch F3 or F4 to move the yellow cursor to a mem-

ory number (“M1” to “M5”) to save, and press switch F6.
The setting is saved by the above operation.
Memory - call up
1. Press switch F1 on the “Mode Select” screen.
The mode memory call screen is displayed.
2. Press switch F3 or F4 to move the yellow cursor to a mem-

ory number (“M1” to “M5”) to call up.
As the cursor is set to the number, the setting stored in the
memory is displayed in the right side of the screen.
3. Call up the selected setting by pressing switch F6.
3-44
REVERSE SLOW MODE SWITCH

The reverse slow mode switch is used for setting and canceling
the reverse slow mode.
While the reverse slow mode is set, reverse slow mode pilot
lamp lights up on the screen of the machine monitor.
When the reverse slow mode is set, it is possible to throttle
down the engine speed automatically to decrease the reverse
speed. Operate the decelerator pedal together, as necessary.
GEAR SHIFT MODE SELECTOR SWITCH

The gear shift mode selector switch changes the gear shift
mode to automatic shift mode or manual shift mode. In the au-
tomatic gear shift mode, the transmission shifts up automatical-
ly to the maximum set gear speed, and shifts down according
to the load.
In the manual gear shift mode, if the auto shift down is ON, the
gear shifts down according to the load, but you are required to
shift up manually.
When the auto shift down is OFF, shift up and down the gear
manually.
Select the Auto Shift Down in the customize mode.
For selection of the customize mode, see “CUSTOMIZE SWITCH (3-43)”.
When the starting switch is turned to ON position, the automatic shift mode is selected by default. The selected
mode is displayed on the gear speed display.
For details and precautions of the gear shift mode, see “SHIFT GEARS (3-171)”.
FUNCTION SWITCHES
The operation of the function switches in the standard screen
3-45
CAMERA IMAGE SELECTOR SWITCH

On the standard screen, press switch F3 to switch to the cam-
era image display.
• On machines not equipped with a camera, the guidance
icon related to switch F3 is not displayed.
Even if switch F3 is pressed, the screen will not switch to
the camera image display.
Other mode operations while camera image is displayed

Even during the camera image is displayed, it is possible to op-
erate following modes.
• The air conditioner can be operated.
When the air conditioner switch is operated, the screen
switches to the air conditioner control screen. When the
screen switches to the air conditioner operation screen,
press switch F6 to return the screen to the camera image.
In addition, if no operation is performed for 5 seconds after
the screen switches to the air conditioner operation
screen, the screen automatically returns to the camera im-
age display.
For details of the air conditioner operation, see “HANDLE
AIR CONDITIONER (3-202)”.
3-46
• It is possible to change the operating mode by pressing

the operating mode selector switch.
For the operating mode selector switch, see “OPERATING
MODE SELECTOR SWITCH (3-43)”.
When the operating mode is changed, the screen returns
automatically to the standard screen.
• It is possible to change the gear shift mode by pressing the

gear shift mode selector switch.
For the gear shift mode selector switch, see “GEAR SHIFT
MODE SELECTOR SWITCH (3-45)”.
When the gear shift mode is changed, the screen returns
automatically to the standard screen.
• It is possible to change the customize setting by pressing

the customize switch.
For the customize switch, see “CUSTOMIZE SWITCH
(3-43)”.
After the customize setting, the screen automatically re-
turns to the standard screen.
• It is possible to stop the alarm buzzer for the warning item

where there is an abnormality, by pressing the buzzer can-
cel switch.
Even if the buzzer cancel switch is pressed, the camera
image display does not switch to another screen or return
to the standard screen.
Depending on the warning, alarm buzzer does not stop
sounding by pressing the buzzer cancel switch.
• It is possible to turn the reverse slow mode ON/OFF by

pressing the reverse slow mode selector switch.
For the reverse travel slow mode selector switch, see “RE-
VERSE SLOW MODE SWITCH (3-45)”.
When the reverse travel slow mode selector switch is
pressed, the screen returns automatically to the standard
screen.
3-47
Actions against warning during camera image display

• If any error or warning occurs on the machine while the
camera image is displayed, the caution lamp flashes at the
top left of the screen.
• If the caution lamp is displayed, press switch F3 to return

to the standard screen, and check the content of the ab-
normality or warning display.
While the caution lamp is flashing, if no lever is operated
for 10 seconds or more, the screen automatically returns
When the screen returns to the standard screen, the cau-
tion lamp at the top left of the screen goes out and an error
or a warning is displayed at the center of the screen.
• If an error is displayed, move the machine, set it in a safe
posture, then have inspection performed immediately.
• For the contents of the warning display, see “WARNING
DISPLAY (3-13)” and “TROUBLES AND ACTIONS
(3-234)”.
3-48
SERVICE METER/CLOCK DISPLAY SELECTOR SWITCH

By pressing switch F4, you can switch the service meter and
clock display on the standard screen.
If you press switch F4 while the clock is displayed, the service

meter is displayed instead of the clock.
If you press switch F4 while the service meter is displayed, the
clock is displayed instead of the service meter.
MULTI GAUGE SELECTOR SWITCH

Multi-gauge display items can be switched by pressing the
function switch F2.
3-49
METHOD FOR USING MULTI GAUGE

The multi-gauge can display the following items.
Multi-gauge selection item Remarks

Engine speed There is a caution
Machine speed -
Work equipment pump pressure -
Battery voltage With caution lamp
Drawbar pull -
Load graph -
Pitch graph -
Clock display -
An approximate value indicated by the multi-gauge is as follows.

Engine speed
(1) 500 rpm
(2) 1000 rpm
(3) 1500 rpm
(4) 2000 rpm
(5) 2750 rpm
(6) 3000 rpm
Travel speed
(1) 0 km/h
(2) 5 km/h
(3) 10 km/h
(4) 15 km/h
Work equipment pump pressure

(1) 0 MPa {0 kg/cm2}
(2) 10 MPa {102 kg/cm2}
(3) 20 MPa {204 kg/cm2}
(4) 30 MPa {306 kg/cm2}
(5) 40 MPa {408 kg/cm2}
(6) 50 MPa {510 kg/cm2}
3-50
Battery voltage
(1) 0 V
(2) 15 V
(3) 20 V
(4) 25 V
(5) 30 V
(6) 31 V
Drawbar pull
(1) 0 W
(2) 0.2 W
(3) 0.4 W
(4) 0.6 W
(5) 0.8 W
(6) 1.0 W
Load graph
Horizontal axis (X) indicates the time, and vertical axis (Y) indi-
cates the drawbar pull.
Similarly to the ECO gauge, it is recommended to use in green
range (G).
The graphs on the screen are updated and scrolled to the left
at intervals of several seconds. (The latest information is dis-
played at the right end.)
Pitch graph
Horizontal axis (X) indicates the time, and vertical axis (Y) indi-
cates the pitch angle of the machine.
The graphs on the screen are updated and scrolled to the left
at intervals of several seconds. (The latest information is dis-
played at the right end.)
Clock display
3-51
USER MENU DISPLAY SWITCH

On the standard screen, press switch F6 to display the user
menu screen on which you can make various settings for the
machine in the monitor display.
USER MENU
The user menu consists of the following kinds. Press switches
F1 and F2 to move to right and left for selecting menu screens.
(a) “Energy Saving Guidance”
(b) “Machine Setting”
(c) “Aftertreatment Devices Regeneration”
(d) “SCR Information”
(e) “Maintenance”
(f) “Monitor Setting”
(g) Mail Check
These menus (a) to (g) are for setting and confirming the fol-
lowing items:
For operations in each menu, see the detailed explanation pa-
ges of respective items.
(a) “Energy Saving Guidance”

• Check of operating record
• Check of ECO guidance record
• Check and reset of fuel consumption record
• Display setting
3-52
(b) “Machine Setting”

• Fan reverse mode
• Auto idle stop timer setting
(c) “Aftertreatment Devices Regeneration”

• Setting for regeneration disable
• Operation of manual stationary regeneration
(d) “SCR Information”

• Check of DEF level
• Information on DEF system
(e) “Maintenance”
• Check and reset of various maintenance times
(f) “Monitor Setting”

• Screen Adjustment
• Screen Adjustment (camera)
• Clock adjustment
• Language selection
• ID key information
• Operator ID
3-53
(g) Mail Check

• Check of mail contents and reply to mail
Operation on user menu screen

On the user menu screen, it is possible to perform the following
operations with switches F1 to F6.
F1: Moves to the left menu. When on the left end menu, it
moves to the right end menu.
F2: Moves to the right menu. When on the right end menu, it
moves to the left end menu.
F3: Moves to the next item (1 line below). When on the last
line, it moves to the first line on the next page.
F4: Moves to the previous item (1 line above). When on the
first line, it moves to the last line on the previous page.

F6: Displays the setting screen for selected item.
• If no switch is operated for 30 seconds on the user menu
screen, the screen automatically returns to the previous
screen.
3-54
ENERGY SAVING GUIDANCE

Each item of “Energy Saving Guidance” menu (a) is used for
displaying and setting the notification relevant to energy saving.
CHECK OPERATION RECORDS

Select “Operation Records” (1) from “Energy Saving Guidance”
menu screen, then press switch F6.
On “Operation Records” menu, the working hours, Average
Fuel Consumption, Actual working hours, Ave. Fuel Consump-
tion (Actual Working), Fuel Consumption, Idling Hours and E
mode time ratio on daily basis or on a split measurement peri-
od basis are displayed.
Operation on the Operation Records screen

On “Operation Records” screen, you can perform the following
operations by pressing switch F3 to F5.
F3: Displays the next page. When on the last page, it displays
the first page.
F4: Displays the previous page. When on the first page, it dis-
plays the last page.
F5: Returns the screen to “Energy Saving Guidance” menu
screen.
3-55
CHECK ECO GUIDANCE RECORD

Select “ECO Guidance Records” (2) from “Energy Saving Guid-
ance” screen, then press switch F6.
On the “ECO Guidance Records” menu, display the frequency
of display of the ECO guidance on a daily basis or during the
split measurement period.
Operations on “ECO Guidance Records” screen

Press switch F5 to perform the following operation on the “ECO
Guidance Records” screen.
F5: Returns the screen to the “Energy Saving Guidance”
screen.
REMARK
ECO guidance denotes displaying the guidance for energy sav-
ing operation. This display may appear on the standard screen
while the machine is in operation.
For detail, see “GUIDANCE DISPLAY (3-32)”.
CHECK FUEL CONSUMPTION RECORD

Select the Average Fuel Consumption Record (3) from the En-
ergy Saving Guidance menu screen, then press switch F6.
On the Average Fuel Consumption Record menu, display the
graph of hourly average fuel consumption during the last 12
hours or the graph of daily fuel consumption during the last 1
week.
3-56
Operation on the Average Fuel Consumption Record screen

Press switch F1, F2 or F5 on the Average Fuel Consumption
Record screen to perform the following operations.
F1: Clears the graph data.
F2: Switches graphical displays of the average fuel consump-
tion.
F5: Returns the screen to the Energy Saving Guidance menu
screen.
REMARK
The displayed value of fuel consumption may differ from the
actual value due to the operating conditions of the customers
(fuel, weather or work contents, etc.).
Switching of displayed graph

Press F2 on the Average Fuel Consumption Record screen to
change the currently displayed graph to another.
REMARK
There are 2 types of graphs. One shows hourly average fuel
consumption during the last 12 hours and the other is daily
average fuel consumption during the last 1 week. Switching be-
tween them is available.
3-57
Deleting the average fuel consumption records

1. When switch F1 (CLEAR) is pressed, the reconfirmation
screen shown in the figure is displayed.
2. When the switch F6 is pressed, graphs of data of the last
12 hours and the last 1 week are both deleted, and the
screen returns to the Average Fuel Consumption Record
screen.
REMARK
Press switch F5 to cancel the data deletion (clear) operation.
CHANGE DISPLAY SETTING

Select Configurations (4) from the Energy Saving Guidance
On the Configurations menu, following operations are availa-
ble.
• Setting the Average Fuel Consumption Display
• Switching ON/OFF of the ECO Gauge Display
• Setting the ECO Gauge Display Fuel Target Value
• Switching ON/OFF of the ECO Guidance Display
• Switching ON/OFF of the ECO Guidance Display at Key
OFF
Operations on the Configurations screen
On the Configurations screen, it is possible to perform the fol-
lowing operations with switches F3 to F6.
F5: Returns the screen to the Energy Saving Guidance menu
screen.
3-58
SET DISPLAY OF FUEL CONSUMPTION GAUGE

It is possible to change the display of fuel consumption gauge
(5) and the setting of Display/Non-display.
1. Select “Average Fuel Consumption Display” (6) from “Con-

figurations” screen, then press switch F6.
On this screen, it is possible to perform the following oper-
ations with switches F3 to F6.
F4: Moves to the previous item (1 line above). When on
the first line, it moves to the last line on the previous
page.
F5: Cancels the setting and returns to “Configurations”
screen.
F6: Changes the setting and returns to “Configurations”
screen.
2. The “Average Fuel Consumption Display” screen appears.
• “1 Day”
Displays the average fuel consumption from 0:00 a.m.
of the day to 0:00 a.m. of the next day.
• “Split Time”
Displays the average fuel consumption during the split
measurement period.
Select “Split Time” to start the automatic measurement of fuel consumption.
• “Not Use”
Does not display the fuel consumption gauge.
3-59
REMARK
When you select the split measurement, measurement stop
switch F1 (“STOP”) is displayed on the “Operation Records”
screen and the “ECO Guidance Records” screen.
When you stop the measurement, select “Operation Records”
(1) screen or “ECO Guidance Records” (2) screen on “Energy
Saving Guidance” menu (a).
Move to each screen, press measurement stop switch F1
(“STOP”).
SWITCH DISPLAY/NON-DISPLAY OF ECO GAUGE

You can specify the item to be displayed on display (7) of the
standard screen.
3-60
1. Select “ECO Gauge display” (8) from “Configurations”

screen, then press switch F6.
2. The “ECO Gauge Display” screen appears.
“Traction”: Displays drawbar pull gauge (A) on the stand-
ard screen.
“Fuel Consump”: Displays ECO gauge (B) on the standard
screen.
“OFF”: Displays nothing on display (7).
On this screen, it is possible to perform the following operations

with switches F3 to F6.
F5: Cancels the setting and returns to “Configurations” screen.
F6: Changes the setting and returns to “Configurations” screen.
SET TARGET FUEL CONSUMPTION VALUE DISPLAYED IN ECO GAUGE

It is possible to change the target fuel consumption value (the upper limit value of the green range) of the ECO
gauge (7).
1. Select the ECO Gauge Display Fuel Target Value (9) on
the Configurations screen, then press switch F6.
2. ECO Gauge Display Fuel Target Value appears.

F3: Decreases the target fuel consumption value by 1 ℓ/h.
F4: Increases the target fuel consumption value by 1 ℓ/h.
F5: Cancels the setting and returns to Configurations
screen.
F6: Changes the setting and returns to Configurations
screen.
3-61
SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE

It is possible to change the setting of Display/Non-display of
ECO guidance (10).
1. Select “ECO Guidance display” (11) from “Configurations”

2. “ECO Guidance Display” setting screen appears.
ON: Displays ECO Guidance (10) on the standard screen.
OFF: Does not display ECO Guidance (10) on the stand-
ard screen.

F5: Cancels the setting and returns to “Configurations” screen.
F6: Changes the setting and returns to “Configurations” screen.
SWITCH DISPLAY/NON-DISPLAY OF GUIDANCE WHEN KEY IS OFF

It is possible to change the setting of Display/Non-display of
guidance (12) when the starting key is turned off.
1. Select ECO Guidance Display at Key OFF (13) from the

Configurations screen, then press switch F6.
3-62
2. The setting screen for ECO Guidance Display at Key OFF

screen appears.
ON: Displays ECO Guidance (12) on the end screen.
OFF: Does not display ECO Guidance (12) on the end
screen.
line, it moves to the first line.
the first line, it moves to the last line.
F5: Cancels the setting and returns to Configurations screen.
F6: Changes the setting and returns to Configurations screen.
MACHINE SETTINGS
Each item of this menu (b) is used for setting items of machine.
REVERSE HYDRAULIC FAN

NOTICE
• After stopping the engine, check around the engine for
sticking dry leaves or dirt.
In particular, carefully check around the exhaust mani-
fold and turbocharger for sticking dirt which can
cause a fire.
• If the aftertreatment devices regeneration pilot lamp
(A) lights up while the fan is rotated in reverse, the en-
gine speed may decrease to 1000 rpm, regardless of
the position of the fuel control dial.
In this case, the fan speed decreases and sufficient air
flow for cleaning the radiator cannot be obtained. Ac-
cordingly, wait under the current condition until after-
treatment devices regeneration pilot lamp (A) goes
out.
After the lamp goes out, the engine speed increases
and the fan can rotate in reverse.
3-63
REMARK
If the fan reverse operation is performed while aftertreatment
devices regeneration pilot lamp (A) is lit, the engine speed may
not increase even if the fuel control dial is set to High idle
(MAX) position, but this is not a failure.
The hydraulic fan reverse mode (fan reverse rotation) can be
used to remove insects and dirt sticking to the radiator core by
blowing air to the outward of the machine with the fan.
Before starting the hydraulic fan reverse, check that there is no
combustible substance in the periphery which may be sucked
in the fan.
In a cold circumstance, perform the cleaning by fan reverse rotation within less than 5 minutes. If the fan re-
verse rotation is performed for a long time, DEF hose may freeze.
1. Set the parking brake lever and work equipment lock lever in LOCK position.
2. Perform the engine warm-up operation.
If the warm-up operation is not performed, the air flow may be insufficient.
3. After finishing the warm-up operation, set the fuel control dial to Low idle (MIN) position.
4. Stop the engine.
5. Open the engine side covers on the right and left sides of the machine.
6. Turn the starting switch to ON position.
7. Select “Fan Reverse Mode” (1) on “Machine Setting” menu
(b) screen.
8. Press switch F6.

If the parking brake lever or work equipment lock lever is in
FREE position or the engine is running, the screen shown
in the figure is displayed and the fan rotation is not re-
versed.
9. Press switch F6 when the fan reversing confirmation

screen is displayed.
When canceling the fan reversing operation, press switch
F5.
3-64
10. Since fan reverse rotation is set, start the engine.
After the engine is started, the machine monitor screen

displays as shown in the figure.
If the parking brake lever or work equipment lock lever is

set to FREE position while the fan is rotated in reverse, the
screen shown in the figure is displayed.
In this case, stop the fan reverse rotation by returning the
parking brake lock lever and work equipment lock lever to
LOCK positions or by pressing switch F5.
11. After finishing the work, press switch F5 and stop the fan
reverse rotation.
12. Set the fuel control dial to Low idle (MIN) position.
13. Turn the starting switch to OFF position to stop the engine.
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AUTO IDLE STOP TIMER SETTING

The auto idle stop function stops the engine automatically when the engine is operated continuously at idle with
the lock lever in LOCK position for a set time.
The auto idle stop function operates when the following conditions are satisfied.
• The engine is running normally.
• The parking brake lever and work equipment lock lever are in LOCK positions.
• The engine coolant temperature, hydraulic oil temperature, and power train temperature are high, and there
is no need of idling to cool them.
• The engine is not in warm-up operation.
• The exhaust gas aftertreatment devices are not being regenerated.
• The parts of DEF system are not in thawing control mode.
• The Fan Reverse Mode is not being operated.
You can set the time to operate the auto idle stop function on the “Auto Idle Stop Timer Setting” screen.
1. Select “Auto Idle Stop Timer Setting” (2) on the “Machine
Setting” menu (b) screen, and then press switch F6.
2. Select the set time on the “Auto Idle Stop Timer Setting”
screen shown, and then press switch F6.
On “Auto Idle Stop Timer Setting screen”, it is possible to
perform the following operations with switches F3 to F6.
the first line, it moves to the last line on the previous
page.
F5: Cancels the selection and returns the screen to the
Machine Setting menu screen.
F6: Allocates the selected setting to that of the Auto Idle Stop Timer Setting.
REMARK
• Choosing “OFF” disables operation of the auto idle stop function.
• You cannot select a time longer than that specified in the Service Menu.
3. When the idling time reaches 30 seconds before the set
time, the monitor returns to the standard screen and
changes to the countdown screen.
At this time, the engine speed is fixed to Low idle (MIN)
position.
If you set the parking brake lever or work equipment lock
lever to FREE positions, countdown stops and the screen
returns to the standard screen.
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4. When countdown reaches 0, the engine stops and the

screen changes to the “Auto Idle Stop in Operation”
screen.
5. To prevent battery discharging, turn off unnecessary
switches.
REMARK
While the auto idle stop is activated, only the engine is
stopped and the machine monitor, inverter, etc., as well as
the electrical components including the air conditioner, ra-
dio, lamps, and wipers keep their states before the engine
is stopped.
To prevent battery discharging, turn the starting switch to
OFF position.
6. When restarting the engine, turn the starting switch as usual.
AFTERTREATMENT DEVICES REGENERATION

Each item of “Aftertreatment Devices Regeneration” menu (c)
is for settings of the aftertreatment devices regeneration.
For details of the aftertreatment devices regeneration, see
“HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-104)”.
The operation methods and the contents of the display of
KDPF regeneration and urea SCR regeneration are common.
SCR INFORMATION
Each item in “SCR Information” menu (d) is for displaying the
information related to SCR and DEF.
For details of SCR Information, see “HANDLE UREA SCR
SYSTEM WARNING (3-114)”.
MAINTENANCE SCREEN SETTING

Each item of setting menu (e) on “Maintenance” screen is used
for displaying and setting the notification relevant to mainte-
nance.
The items on the “maintenance” display are as follows.
A B
Air Cleaner Cleaning or Change -
Coolant Change -
Fuel Prefilter Change 500
Engine Oil Change 500
Engine Oil Filter Change 500
P/T Oil Filter Change 500
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A B
Fuel Main Filter Change 1000
Final Drive Oil Change 1000
Hyd Oil Tank Breather Change 1000
P/T Oil Change 1000
Fuel Tank Breather Change 1000
DEF Tank Breather Change 1000
Hydraulic Oil Filter Change 2000
Damper Case Oil Check and Change 2000
Hydraulic Oil Change 2000
KCCV Filter Change 2000
DEF Filter Change 2000
KDPF Filter Cleaning 4500
DEF Tank Washing 4500
A: Maintenance items
B: Default maintenance interval settings (h)
C: Time remaining until maintenance (h)
On the “Maintenance” screen, it is possible to perform the following operations with switches F1 to F6.
F1, F2: Moves to the right and left menus.
F3: Moves to the next item (1 line below). When on the last line, it moves to the first line on the next page.
F4: Moves to the previous item (1 line above). When on the first line, it moves to the last line on the previous
page.
F6: If this switch is kept pressed, the screen changes to the screen for resetting the remaining time to the main-
tenance for the selected item.
REMARK
When resetting the remaining time to the maintenance, keep switch F6 pressed for at least 1.5 seconds. If this
time is short, the switch operating sound can be heard, but the screen does not switch to the screen for reset-
ting the remaining time to the maintenance.
• If no switch is operated for 30 seconds on the “Maintenance” screen, the screen automatically returns to the
standard screen.
• When the maintenance time caution lamp is lit on the standard screen, press switch F6 on the standard
screen and the screen automatically displays the “Maintenance” screen.
• On the “Maintenance” screen, if the time remaining to the maintenance for any item is less than 30 hours
(initial setting value), the remaining time display (c) is highlighted in yellow. If the time remaining to the
maintenance is less than 0 hour, display (c) is highlighted in red.
• If you want to change the setting for the maintenance time or maintenance notice time (initial setting: 30
hours), consult your Komatsu distributor.
Operations on the “Maintenance Due Time Reset” screen
On the “Maintenance” screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the
“Maintenance Due Time Reset” screen.
Reset the remaining time to the maintenance on this screen.
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1. Press switch F6 on the “Maintenance Due Time Reset”

screen.
The screen switches to the reconfirmation screen.
REMARK
• When canceling the reset, press switch F5. The
screen returns to the “Maintenance” screen.
• On the “Maintenance Due Time Reset” screen, if no
switch is operated for more than 30 seconds, the
screen automatically changes to the “Maintenance”
screen.
2. The reconfirmation screen is displayed.
If switch F6 is pressed again, the remaining time is reset
and the screen switches to the “maintenance” screen.
REMARK
• When canceling the reset, press switch F5. The
screen returns to the “Maintenance” screen.
• On the reconfirmation screen, if no switch is operated
for more than 30 seconds, the screen automatically
returns to the “Maintenance” screen.
MONITOR SETTINGS
Each item of “Monitor Setting”menu (f) is to make settings for
the monitor.
SCREEN ADJUSTMENT
Use the “Screen Adjustment” menu to adjust brightness of the monitor screen.
1. Select “Screen Adjustment” (1) on the “Monitor Setting”
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2. Use switches F2 to F6 to adjust brightness of the screen.

F2: Resets an adjusted value to default value.
F3: Moves the indicator to the left by one notch.
F4: Moves the indicator to the right by one notch.
F5: Cancels the change and returns to the “Monitor Set-
ting” menu screen.
F6: Accepts the change and returns to the “Monitor Set-
REMARK
• If the light switch is at night mode ON, and the screen
is adjusted, it is possible to adjust the brightness of
the monitor screen (night mode).
• If the light switch is at day mode ON, and the screen is
adjusted, it is possible to adjust the brightness of the
monitor screen (day mode).
• As long as "*" mark is displayed in the upper right cor-
ner of the screen, brightness is automatically restrict-
ed by the machine monitor to protect the liquid crystal.
Screen adjustment may not change the screen bright-
ness as long as "*" mark is displayed. However, it is
not an error.
SCREEN ADJUSTMENT (CAMERA)

k CAUTION
Never drive the machine (in reverse) while watching only the camera screen. Be sure to visually check
the safety around the machine.
The guide lines indicate blade width lines and a line 5 m away from the rear of the machine. When
changing the blade, ask your Komatsu distributor for adjustment of the camera screen.
1. Select camera screen adjustment on the monitor setting

menu screen.
2. Press switch F6.
On the Screen Adjustment screen, the following items related

to the camera screen can be set.
• Camera image screen brightness adjustment
• Camera view mode setting (Setting of Reverse Synchroni-
zation)
• Guide line display mode setting
F4: Moves to the previous item (1 line above). When on the first line, it moves to the last line.
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F5: Cancels the change of setting and returns to the monitor setting menu screen.
F6: Changes the setting and returns to the monitor setting menu screen.
ADJUST CAMERA IMAGE BRIGHTNESS

1. Select “Brightness Adjustment” on “Screen Adjustment
(Camera)” menu.
2. Press switch F6.
3. Use switches F2 to F6 to adjust brightness of the screen.

F2: Resets an adjusted value to default value.
F3: Moves the indicator to the left by one notch.
F4: Moves the indicator to the right by one notch.
F5: Cancels the change and returns the screen to “Screen
Adjustment (Camera)” menu.
F6: Accepts change and returns to the “Screen Adjustment
(Camera)” menu.
REMARK
As long as “*” mark is displayed in the upper right corner of the
screen, brightness is automatically restricted by the machine
monitor to protect the liquid crystal. Screen adjustment may not
change the screen brightness as long as “*” mark is displayed.
However, it is not an error.
SET DISPLAY MODE

(Reverse Synchronization setting)
1. Select “Camera View Mode” on “Screen Adjustment (Cam-
era)” menu.
2. Press switch F6.
3. The “Camera View Mode” setting screen is displayed.

• “Normal”: Switch F2 of the function key is used to
change the screen to the camera screen.
• “Reverse Synchronization”: Camera screen is auto-
matically displayed when the gear shift lever is set to
reverse.
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F4: Moves to the previous item (1 line above). When on the first line, it moves to the last line on the previous
page.
F5: Cancels the setting and returns to the “Screen Adjustment (Camera)” screen.
F6: Change the setting and returns to the “Screen Adjustment (Camera)” screen.
SET GUIDE LINE DISPLAY MODE

1. Select the “Guide Line” on the “Screen Adjustment (Cam-
era)” screen.
2. Press switch F6.
3. The “Guide Line” setting screen is displayed.

• OFF: Guide lines (Outline (A), Center Line (B)) are not
displayed.
• Outline: Only outlines (A) that indicate the machine
width and the distance from the rear end of the ma-
chine are displayed.
• Center Line: Only machine center line (B) is displayed.
• All : Both of Outline (A) and Center Line (B) are dis-
played.
first line, it moves to the last line.
F5: Cancels the setting and returns to the “Screen Adjustment
(Camera)” screen.
F6: Change the setting and returns to the “Screen Adjustment
(Camera)” screen.
CLOCK ADJUSTMENT
The “Clock Adjustment” menu is used to change the setting of the clock displayed on the standard screen of the
monitor.
1. Select “Clock Adjustment” (3) on the “Monitor Setting”
menu screen.
2. Press switch F6.
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3. The screen switches to the “Clock Adjustment” screen for

selecting a menu.
The following 5 items can be changed.
(a): “GPS Synchronization”
(b): “Calendar”
(c): “Time”
(d): “12h/24h Mode”
(e): “Daylight Saving Time”
REMARK
• (b) Calendar and (c) Time need to be readjusted since
they are reset after a long-term storage.
• When the GPS Synchronization is set to ON, they are
automatically readjusted.
4. Perform the following setup procedure by operating switches F3 to F6 on the Clock Adjustment screen for
selecting a menu.
GPS SYNCHRONIZATION SETTING

On machines equipped with KOMTRAX, turning on “GPS Syn-
chronization” menu enables automatic setting of the monitor's
date and time in accordance with the clock of GPS.
F3: Moves to the next item (1 line below). Moves to the top line
when on the bottom line.
F4: Moves to the previous item (1 line above). Moves to the
bottom line when on the top line.
F5: Cancels change and returns to “Clock Adjustment” screen.
REMARK
• When the machine is in the environment where the radio
waves from GPS cannot be received, such as inside of a
building, the automatic setting function may not work.
• While“GPS synchronization” menu is turned on, the menu
for “Calendar” (b) and “Time” (c) cannot be selected.
CALENDAR SETTING
Adjust the date of the monitor.
REMARK
As long as “GPS Synchronization” menu is turned on, “Calendar” menu is not selectable.
1. Select “Calendar” (b) on “Clock Adjustment” screen, then
press switch F6.
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2. The “Calendar” screen is displayed.

When year display (A) is highlighted in yellow, operate the
switches as follows to change year display (A). If it is not
necessary to change the year setting, press switch F6.
F3: Calendar goes back 1 year.
F4: Calendar advances 1 year.
F5: Cancels change and returns the screen to “Clock Ad-
justment” screen.
F6: Proceeds to setting for month
3. When month display (B) is highlighted in yellow, operate
the switches as follows to change month display (B). If it is
not necessary to change the month, press switch F6.
F3: Calendar goes back 1 month.
F4: Calendar advances 1 month.
F5: Cancels change and returns to the year setting screen.
F6: Proceeds to setting for date.
4. When date display (C) is highlighted in yellow, operate the

switches as follows to change day display (C). If it is not
necessary to change the day, press switch F6.
F3: Calendar goes back 1 day.
F4: Calendar advances 1 day.
F5: Cancels change and returns to the month setting
screen.
F6: Accepts change and returns the screen to “Clock Ad-
justment” screen.
TIME SETTING
Adjust the time of the monitor clock.
REMARK
As long as “GPS Synchronization” is turned on, “Time” menu is not selectable.
1. Select “Time” (c) on “Clock Adjustment” screen, then press
switch F6.
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2. The “Time” screen is displayed.

When the hour display (D) is highlighted in yellow, operate
the switches as follows to change hour display (D). If it is
not necessary to change the hour setting, press switch F6.
F3: The time goes back 1 hour.
F4: The time advances 1 hour.
F5: Cancels change and returns the screen to “Clock Ad-
justment” screen.
F6: Proceeds to setting for the minute.
3. When minute display (E) is highlighted in yellow, operate
the switches as follows to change minute display (E). If it is
not necessary to change the minute, press switch F6.
F3: The time goes back 1 minute.
F4: The time advances 1 minute.
F5: Cancels change and returns to the time setting screen.
justment” screen.
SWITCH 12H/24H DISPLAY MODE

Choose either a 12-hour display (AM/PM) or a 24-hour display.
• 24-hour system display
• 12-hour system display (AM/PM)
1. Select “12h/24h Mode” (d) on “Clock Adjustment” screen,
then press switch F6.
2. “12h/24h Mode” screen appears.

F3: Moves to the next item (1 line below). Moves to the top
line when it is on the bottom line.
F4: Moves to the previous item (1 line above). Moves to
the bottom line when it is on the top line.
F5: Cancels the change and returns the screen to “Clock
Adjustment” screen.
F6: Accepts change and returns to “Clock Adjustment”
screen.
DAYLIGHT SAVING TIME (SUMMER TIME) SETTING

If “Daylight Saving Time” is turned on, the clock display becomes 1 hour forward. If “Daylight Saving Time” is
turned off, the clock display returns to the set time.
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1. Select “Daylight Saving Time” (e) on “Clock Adjustment”

2. The “Daylight Saving Time” screen is displayed.

F3: Moves to the next item (1 line below). Moves to the top
line when on the bottom line.
F4: Moves to the previous item (1 line above). Moves to
the bottom line when on the top line.
F5: Cancels change and returns to “Clock Adjustment”
screen.
justment” screen.
REMARK
Daylight saving time or summer time means moving the
clock forward an hour to take advantage of the fact that the
sun rises early in summer in our daily life.
LANGUAGE SETTINGS
On the language setting menu, it is possible to select the language used on the monitor display.
The languages that can be selected are as follows.
English, Japanese, French, Spanish, Portuguese, Italian, German, Swedish, Dutch, Danish, Norwegian, Fin-
nish, Icelandic, Czech, Hungarian, Polish, Slovak, Slovene, Romanian, Croatian, Estonian, Latvian, Lithuanian,
Bulgarian, Greek, Turkish, Serbian
1. Select “Language” (4) on the monitor setting menu, then
press switch F6.
2. Select the language to use for the display, then press

switch F6. The screen display changes to the selected lan-
guage.
On the “Language” screen, it is possible to perform the fol-
lowing operations with switches F3 to F6.
F3: Moves to the item below.
F4: Moves to the item above.
F5: Cancels change and returns to the monitor setting
screen.
F6: Accepts change and returns to the monitor setting
screen.
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OPERATOR ID
You can check and change the “Operator ID” which is under identification on the “Operator ID” menu.
The “Operator ID” menu is not displayed when the operator identification function is disabled.
REMARK
Contact your Komatsu distributor for details of the method of setting, changing, or cancelling the operator identi-
fication function.
WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP

When the starting switch is ON and ID is inputted, the identified
ID is displayed in the column of “Operator ID” on the “Monitor
Setting” menu screen.
When the starting switch is ON and “SKIP” is selected, “****” is

displayed in the column of “Operator ID” on the “Monitor Set-
1. Select “Operator ID” (5) on the “Monitor Setting” menu

screen, then press switch F6 for 1 second.
2. The “Operator ID Change” screen is displayed.
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• Input the already registered ID on the “Operator ID

Change” screen and press F6. Then, the identified ID
can be changed.
A message is displayed below and the screen returns
to the “Monitor Setting” menu screen.
On the “Monitor Setting” menu screen, the inputted ID
is displayed in the column of “Operator ID”.
• When you press switch F1 on the “Operator ID

Change” screen, a message is displayed below and
the screen returns to the “Monitor Setting” menu
screen.
On the “Monitor Setting” menu screen, as the same
way when the starting switch is ON and “SKIP” is se-
lected, “****” is displayed in the column of “Operator
ID”.
In this case, the operator ID is not identified.
• When you press switch F6 after inputting the ID which

is not registered to the “Operator ID Change” screen,
a message is displayed below and the screen returns
In this case, the identified ID is not changed.
• On the “Operator ID Change” screen, if no switch is
operated for more than 30 seconds, the screen auto-
matically changes to the “Monitor Setting” menu
screen.
WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP

When the operator identification function is available without
SKIP, the identified ID number is not displayed in the “Operator
ID” column of “Monitor Setting” screen.
1. Select “Operator ID” (5) on the “Monitor Setting” menu

screen, then press switch F6 for 1 second.
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2. The “Operator ID Change” screen is displayed.
• Input the already registered ID on the “Operator ID

Change” screen and press F6. Then, the identified ID
can be changed.
A message is displayed below and the screen returns
• When you press switch F6 after inputting the ID which

is not registered to the “Operator ID Change” screen,
a message is displayed below and the screen returns
• On the “Operator ID Change” screen, if no switch is
operated for more than 30 seconds, the screen auto-
matically changes to the “Monitor Setting” menu
screen.
MESSAGE DISPLAY
On machines equipped with KOMTRAX, you can see the mes-
sages from your Komatsu distributor on this User Message
menu (g).
When there is any message, the User Message at the top of

the standard screen lights up.
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Message is distinguished as follows according to the lighting

states of User Message (1).
Lights up in green (A): There is unread message.
Lights up in blue (B): There is any read message to which no
reply is made.
OFF: No messages
REMARK
• When the message display lights up in blue (B), it means
that no reply has been made yet to any read message to
your Komatsu distributor. Reply to the message in accord-
ance with the replying method mentioned below:
• If the starting switch is turned to OFF position when there
is any unread message, the message will be displayed on
the end screen, and when the monitor is started next time,
the message will change to a read message (the message
display: lights up in blue (B)).
• The message will be deleted when it becomes out of date
or when a new message arrives.
CHECK MESSAGE
1. On the standard screen, press switch F6.
When there is any message, message display (1) lights
up.
While message display (1) is lit, press switch F6, and the
mail confirmation menu (g) directly opens.
Select the mail confirmation menu (g), and you can read
the received message.
2. If a message requests reply, the “Numeric Input: []” box (2)

is displayed. Make any reply to the message.
REMARK
• (3) is the subject of the received message. When no
message is received, “No message.” is displayed in
place (3).
• (4) is the serial number of received messages.
REPLY TO MESSAGE
1. Input the selected item number in the “Numeric Input: []” box (2) on the screen of mail confirmation menu
(g).
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The selected item number is written in place (5) of the

message text.
• Input the number by using the monitor panel switch.
Each switch corresponds to the value shown on the
right side below the switch.
• If you input an incorrect number, press switch F5, and
you can clear an input character at a time.
• If switch F5 is pressed when the input column is blank,
the screen returns to the standard screen.
2. After inputting a selected item number, press switch F6.
3. When the message “Do you send Numeric Input?” is dis-
played in the column (2) of the mail confirmation menu (g)
screen, press switch F6 again. The input value will be sent
out.
If switch F5 is pressed when the message “Do you send
Numeric Input?” is displayed, the message reply screen
will appear. At this time, the previous input value will be
cleared.
SWITCHES
(1) Cigarette lighter (24V) (6) Starting switch

(2) Fuel control dial (7) Horn switch
(3) Rear lamp switch (8) Room lamp switch
(4) Headlamp switch (9) Wiper switch
(5) Engine shutdown secondary switch
3-81
STARTING SWITCH
Starting switch is used to start or stop the engine.
(A): OFF position
The key can be inserted or withdrawn. Switches for the electri-
cal system (except room lamp) are all turned off, and the en-
gine is stopped.
(B): ON position
Electric current flows through the charging and lamp circuits.
Keep the switch at this position while the engine is running.
(C): START position
This is the position to start the engine. Keep the key at this position during cranking and release it immediately
after the engine starts.
When the switch is released, it automatically returns to ON position (B).
(D): HEAT (preheating) position
This is the position to start preheating manually.
When the key is turned to HEAT (preheating) position (D), the HEAT pilot lamp lights up and preheating starts.
When the preheat pilot lamp changes from lighting to flashing, release the key immediately.
When the switch is released, it automatically returns to OFF position (A).
Turn the starting switch key to START position (C) and start the engine immediately.
FUEL CONTROL DIAL

Fuel control dial is used to control the engine speed and out-
put.
(a) Low idle (MIN)
The position where the dial is turned fully to the left.
(b) High idle (MAX)
The position where the dial is turned fully to the right.
REMARK
• When stopping the engine, turn the fuel control dial to the
Low idle (MIN) position and then turn the starting switch to
OFF position.
• Even if the engine is started with the fuel control dial in a
position other than Low idle (MIN) position, the engine
speed is set to low idle.
In this case, you can change the engine speed by turning
the fuel control dial to Low idle (MIN) position and then
turning it toward High idle (MAX) position.
CIGARETTE LIGHTER
The cigarette lighter is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its origi-
nal position after a few seconds, so pull it out to use it.
If the cigarette lighter is removed, the socket can be used as an
120 W (24 V x 5 A) power source.
NOTICE
This cigarette lighter is for 24 V. Do not use it as a power
supply for 12 V equipment.
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REMARK
Use the cigarette lighter while engine is running.
WIPER SWITCH
The wiper switch operates the windshield wiper.
The wiper switches are as follows.
(LH) Left door
(FF) Front window
(RH) Right door
(RR) Rear window
(INT) Wiper intermittent operation switch
REMARK
If the wiper blade is locked for some reason, the wiper stops
automatically.
The wiper starts again automatically after a certain period. Be
sure to remove the cause of stop, however.
Examples of causes of stop
• Long operation while glass is half dry
• Foreign material caught in arm or blade
• Snow or ice sticking to arm or blade
This switch is also used as the window washer switch.
The switch is operated as follows.
Switches (LH), (FF), (RH), and (RR)
(a) ON position
The wiper operates.
(b) Washer operating position
While the switch is depressed, the washing water is sprayed
and wiper operates at the same time.
When the switch is released, it returns to (a) position, washing
water stops, and only wiper operates.
(c) OFF position
The wiper stops.
Switch (INT)
(a) ON position
The wiper operates intermittently when the switch is turned ON.
(b) OFF position
The wiper operates continuously when the switch is turned
OFF.
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REMARK
• When installing the cab, check the colors and install the
washer tank and each window washer hose correctly.
• When installing the cab, perform the operation in accord-
ance with the cab installation procedure manual held by
your Komatsu distributor.
(A) For left (blue)

(B) For right (red)
(C) For rear (black)
(D) For front (colorless)
(E) Washer tube (tank side)

(F) Washer tube (cab side)
(G) Left door (blue)
(H) Right door (red)
(I) Rear window (black)
(J) Front window (colorless)
HORN SWITCH
If you press the horn switch, the horn sounds.
The horn switch is installed at the rear of the blade control lever
on the right of the operator's seat.
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HEAD LAMP SWITCH

The headlamp switch is used to light up the head lamp and
monitor illumination.
(A) Night position
Lamps light up and monitor illumination is set to night mode.
(B) Day position
Lamps light up and monitor illumination is set to day mode.
(C) OFF position
Lamps go out.
(The monitor illumination is set to day mode.)
REAR LAMP SWITCH

Use the rear lamp switch to light up the rear lamp.
(A) ON position
Rear lamp lights up.
(B) OFF position
Rear lamp goes out.
REARVIEW MONITOR BRIGHTNESS ADJUSTMENT SWITCH

The rearview monitor brightness adjustment switch is used to
adjust the brightness of the rearview monitor.
The brightness in the day and night modes can be adjusted in-
dividually.
Position (A)
The rearview monitor becomes brighter.
Position (B)
The rearview monitor becomes darker.
ROOM LAMP SWITCH

NOTICE
If the room lamp is left to be turned on, the batteries may be exhausted. Always turn the switch to OFF
position after using room lamp.
Use room lamp switch to light up the room lamp.
ON position
Lights up
OFF position
OFF
The room lamp lights up even when the starting switch is at
OFF position.
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ENGINE SHUTDOWN SECONDARY SWITCH

NOTICE
The engine shutdown secondary switch is used to stop the engine when the starting switch is turned to
OFF position but the engine does not stop.
• Use the engine shutdown secondary switch only in an emergency.
Immediately ask your Komatsu distributor for repair of the problem.
• If this switch is set to the “STOP ENGINE” position by mistake while the machine is operating nor-
mally, “Engine Shutdown Secondary SW In Operation” is displayed on the machine monitor.
If “Engine Shutdown Secondary SW In Operation” is displayed on the machine monitor, check that
the switch cover is closed and the switch is in the “NORMAL” position. If not, set it to the “NOR-
MAL” position.
1. Raise cover (C) and open it.
2. Turn the engine shutdown secondary switch to upper posi-

tion (a) and the engine stops.
(a) STOP ENGINE
When abnormal (switch is set to upper position)
(b) NORMAL
When normal (switch is set to lower position)
• When cover (C) is closed, the engine shutdown secondary switch automatically returns to the NOR-
MAL position (b).
• When the starting switch is turned to ON position
while the engine shutdown secondary switch is in the
STOP ENGINE position (a), “Engine Shutdown Sec-
ondary SW In Operation” is displayed on the machine
monitor.
If this screen is displayed, return the engine shutdown
secondary switch to the NORMAL position (b).
3-86
CONTROL LEVERS AND PEDALS
(1) Parking brake lever (5) Work equipment lock lever

(2) Joystick (steering, directional and gear shift lever) (6) Blade control lever
(3) Brake pedal (7) Ripper control lever (if equipped)
(4) Decelerator pedal
BLADE CONTROL LEVER

The blade control lever is used to control the blade.
(a) RAISE
(b) HOLD
(c) LOWER
(d) FLOAT
(A) RIGHT tilt
(B) LEFT tilt
3-87
BLADE CONTROL LEVER FOR SIGMADOZER

Lifting operation
(a) RAISE
(b) HOLD: Blade is stopped and held in this position.
(c) LOWER
(d) FLOAT: Blade will move freely according to external force.
Tilting operation
(A) RIGHT tilt
(B) LEFT tilt
Pitching operation
(If equipped)
(EX SIGMADOZER, WX SIGMADOZER)
Operate the blade control lever while pressing pitch button (C).
3-88
(D) Pitch angle in NEUTRAL: Cutting angle is in neutral

(E) FORWARD PITCH: Cutting angle is increased.
REMARK
• The blade can be pitched when lever (7) is in the raise,
hold or lower position.
• When R.H. pitch cylinder is fully retracted (F), the blade
cutting angle (pitch angle) is in the neutral position. When
the cylinder rod is seen large (G), the blade is pitched for-
ward.
• For pushing up operation, use it with forward pitch. This
setting can prevent the dirt from spilling from the bowl on
the front side of the blade or over the blade top.
• When leveling the ground in reverse with the lever in the
float position, set the blade at the neutral blade cutting an-
gle (pitch angle) to finish the ground surface better.
(F) (G)
Position at which R.H. pitch cylinder is fully retracted
Position at which cylinder rod is seen clear
(Position at which cylinder rod starts appearing)
Neutral pitch angle Forward pitch
Pitching control
(if equipped)
(other than EX SIGMADOZER and WX SIGMADOZER)
3-89
Operate the blade control lever while pressing the pitch button
(C).
(D) Rearward pitch: Cutting angle is small.
(E) Forward pitch: Cutting angle is large.
REMARK
• The blade can be pitched when the lever is in the raise,
hold or lower position.
• The blade can be pitched when the blade control lever is
operated to the left (D) or right (E) while pressing the pitch
button (C).
• When the blade is about the neutral cutting angle (pitch
angle), the cylinder rod starts appearing from the right cyl-
inder cover bottom (F position). When the cylinder rod is
seen clearly (G), the blade is pitched forward. When the
cylinder rod is not at all seen (H), the blade is pitched rear-
ward.
• At pushing up operation, set the blade cutting angle (pitch
angle) between the neutral cutting angle to the end of for-
ward pitch angle. This setting can prevent the dirt from
spilling from the bowl on the front side of the blade or over
the blade top.
• When leveling the ground in reverse with the lever in the
float position, set the blade at the neutral blade cutting an-
gle (pitch angle) to finish the ground surface better.
(F) (G) (H)

Position at which cylinder rod starts Position at which cylinder rod is seen Position at which cylinder rod is not at
appearing clearly all seen
Neutral pitch angle Forward pitch Rearward pitch
3-90
BLADE CONTROL LEVER FOR POWER ANGLE POWER TILT DOZER

Lifting operation
(a) RAISE
(c) LOWER
(d) FLOAT: Blade will move freely according to external force.
REMARK
You can perform lifting operation during angling operation, but
the blade speed decreases.
Select the operations according to the type of the work.
Tilting operation
(A) RIGHT tilt
(B) LEFT tilt
REMARK
You can perform tilting operation during angling operation, but
the blade speed decreases.
3-91
Angling control
Operate angle switch (L) forward and backward to angle the
blade.
(C) LEFT angle: Move angle switch (L) backward.
(D) HOLD: Blade is stopped and held in this position.
(E) RIGHT angle: Move angle switch (L) forward.
REMARK
You can perform angling operation during lifting or/and tilting
operations, but the blade speed decreases.
BRAKE PEDAL
k WARNING
Do not rest your foot on the pedal except when you oper-
ate the pedal.
If you depress the brake pedal, R.H. and L.H. brakes are ap-
plied simultaneously.
PARKING BRAKE LEVER

k WARNING
• When leaving the operator's seat, set the parking brake lever securely to LOCK position.
If the parking brake lever is not in LOCK position and the joystick (steering, directional and gear
shift lever) is touched by mistake, it may lead to serious personal injury or death.
• If the parking brake lever is not in LOCK position securely, the parking brake may not be locked.
Check that the parking brake lever is under the state in the figure.
• When leaving the machine, be sure to set the parking brake lever to LOCK position.
• When pulling the parking brake lever up, or pushing down, be careful not to touch the joystick
(steering, directional and gear shift lever).
• Check that your clothes do not get caught by the joystick (steering, directional and gear shift lever).
3-92
The parking brake lever is the lever to control the parking

brake.
When operating the parking brake lever, always use the control
lever (1). Do not operate by holding the red bar (2) on the con-
sole.
(L) LOCK position:
The red bar (2) on the console is lowered, and it indicates that
the parking brake has been applied.
(F) FREE position:
The red bar (2) on the console rises, and it blocks the passage.
It indicates that the parking brake is released.
REMARK
• When setting the parking brake lever to LOCK position, return the joystick (steering, directional and gear
shift lever) to N (Neutral) position.
• When starting the engine, set the parking brake lever to LOCK position.
When the parking brake lever is not in LOCK position, the limit switch operates, and the engine does not
start.
WORK EQUIPMENT LOCK LEVER

k WARNING
• When standing up from the operator's seat, set the work equipment lock lever securely to LOCK po-
sition.
If the work equipment lock lever is not at LOCK position and the blade control lever or ripper con-
trol lever is touched by mistake, it may lead to serious accident.
• If the work equipment lock lever is not set securely to LOCK position, the lock may not be applied.
Check that it is in the position shown in the figure.
• When parking the machine or when performing maintenance, always lower the blade or ripper to the
ground, then set the work equipment lock lever to LOCK position.
• When pulling up or pushing down the lock lever, be careful not to touch the blade control lever or
ripper control lever.
• Check that your clothes do not get caught by the blade control lever or ripper control lever.
The work equipment lock lever is a locking device of the blade

control lever and the ripper control lever.
When operating the work equipment lock lever, always use the
control lever (1). Do not operate by holding the red bar (2) on
the console.
When it is set to LOCK position, the TILT, RAISE, LOWER, and
FLOAT operations are locked.
(L) LOCK position:
The red bar (2) on the console is lowered, and you cannot op-
erate the blade control lever nor ripper control lever.
(F) FREE position:
The red bar (2) on the console rises, and it blocks the passage. The work equipment moves by operating the
blade control lever and the ripper control lever.
REMARK
When starting the engine, always place the work equipment lock lever at LOCK position.
If the work equipment lock lever is not at LOCK position, the limit switch is actuated and the engine will not start.
3-93
JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) (PCCS LEV-

ER)
Perform forward/reverse switching operation, steering opera-
tion, and counter-rotation turn by using the joystick (steering,
directional and gear shift lever).
REMARK
PCCS: Palm command control system
(Electronic steering system)
Forward/reverse switching operation

(a) FORWARD
(N) NEUTRAL
(b) REVERSE
Move to the front to travel forward; move to the rear to travel in
reverse.
Steering operation
(L) Turn LEFT
(N) NEUTRAL
(R) Turn RIGHT
When the lever is tilted halfway in the direction you are turning
while it is tilted in the forward and reverse travel direction, the
machine turns gradually.
If the lever is tilted fully, the machine turns sharply.
REMARK
If the lever is released during steering operation, it returns to
(a) or (b), and the machine travels straight.
Gear shift operation
The gear is shifted by pressing switch (c) or (d) while the joy-
stick (steering, directional and gear shift lever) is in FORWARD
or REVERSE position.
(c) Up switch: The gear is shifted up by 1 step each time this
switch is pressed.
(d) Down switch: The gear is shifted down by 1 step each time
this switch is pressed.
For the maximum travel speed in each speed range, see
“SPECIFICATIONS (5-2)”.
3-94
REMARK
• When the gear is shifted, the current gear speed is displayed in the gear speed display section of the ma-
chine monitor.
(Example)
Neutral: “N” is displayed in the display section.
Forward 2nd: “F2” is displayed in the display section.
Reverse 3rd: “R3” is displayed in the display section.
When the parking brake lever is locked, “P” is displayed.
• For gear shift operation in the preset mode, see “SHIFT GEARS (3-171)”. The preset mode selection is the
operation to set the gear speeds to be selected in advance in N (neutral) position.
Counter-rotation turn
k WARNING
If the R.H. and L.H. loads are uneven during counter-rotation turn, the machine may makes a pivot turn.
Accordingly, check the ground condition and pay attention to interference with obstacles during opera-
tion.
When the lever is tilted halfway in the direction you are turning
while it is in N (neutral) position, the R.H. and L.H. track shoes
rotate in the opposite directions to each other to make a coun-
ter-rotation turn slowly. If the lever is tilted fully, the counter-ro-
tation turn speed increases.
(R) RIGHT counter-rotation turn
(L) LEFT counter-rotation turn
DECELERATOR PEDAL
k WARNING
• Do not place your foot on this pedal unless necessary.
• When passing over the top of a slope or when dump-
ing soil from a cliff, there is danger that the load on the
machine will suddenly be reduced and the travel
speed will increase. In this case, depress the decelera-
tor pedal to reduce the travel speed.
The decelerator pedal is used to reduce the engine speed or

stop the machine.
When changing the travel direction or stopping the machine, depress the decelerator pedal to reduce the travel
speed in advance.
RIPPER CONTROL LEVER

(If equipped)
The ripper control lever is used for operating the ripper.
3-95
(a) RAISE
(b) HOLD: Ripper is stopped and held in this position.
(c) LOWER
OTHER EQUIPMENT
DOOR OPEN LOCK
Use the door lock to fix the door in position after opening it.
1. Push the door against the door catch (1).
The door is fixed to the catch.
2. To release the door, move lever (2) inside the cab to the front of the cab.
The catch releases.
NOTICE
• When keeping the door open, fix it securely to the
catch.
• Always close the door when traveling or performing
operations. If doors are left open, they may be broken.
• Keep the door locked open securely. The doors may
be closed by vibration.
3-96
SASH GLASS INTERMEDIATE LOCK

When working with the cab sash glass open, use this lock to
prevent the glass from chattering.
• When the lever is in FREE position (F), the glass can be
opened or closed.
• When the lever is in LOCK position (L), the glass is held in
position.
CAP AND COVER WITH LOCK

Use the starting switch key to open and close the locks on the caps and covers.
For the locations and opening and closing method of the cap with lock and cover, see “LOCK (3-197)”.
Insert the key as far as it will go to the shoulder (A) and turn it.
If the key is turned when it is not inserted all the way to the
end, it may break.
DOOR POCKET
They are installed to the inside of the right and left doors. Use
them to put something in.
Do not put in heavy things such as tools.
If the pocket is dirty, turn bolts (1) (3 pieces), remove the pock-
et, and wash it in water.
3-97
ASHTRAY
The ashtray is on the left side of the operator's seat.
Always put out your cigarette before putting it in the ashtray
and be sure to close the lid.
POWER SUPPLY OUTLET

Power source inside cab
24V power supply
NOTICE
Do not use this as a power supply for 12V equipment.
This will cause failure of the equipment.
If cigarette lighter (1) is removed, its socket can be used as a
power source.
The capacity of the cigarette lighter is 120W (24V x 5A).
REMARK
Use this power source while engine is running.
12V power source

The capacity of this accessory socket is 144W (12V x 12A).
• When it is used at one place: 144W (12V x 12 A)
• When it is used at 2 places: 144W in total
REMARK
Use this power source while engine is running.
Power source outside cab

24V power supply
NOTICE
• Do not use this as a power supply for 12V equipment.
This will cause failure of the equipment.
• Do not install equipment which exceeds 120W (24V x
5A).
Open the battery inspection cover on the left side of the ma-
chine, and connector (3) for taking out auxiliary power supply is
seen.
(Connector AUX1 can be used.)
3-98
FUSE
NOTICE
When replacing the fuse, be sure to turn the starting switch to OFF position and, after confirming that
the system operating lamp is not lit, set the battery disconnect switch key to OFF position.
• The fuses protect the electrical component and wiring from burning out.
• If the fuse becomes corroded, or looks white powdery, or the fuse is loose in the fuse holder, replace the
fuse.
• Replace the fuse with the one of the same capacity.
Fuse boxes (1) and (2) are installed under the inspection cover
at the front bottom of the console box on the left side of the op-
erator's seat.
Fuse box (3) is installed to the overhead panel.
Fuse capacities and circuit names

Fuse box (1)
Fuse ca-
No. Name of circuit
pacity
(1) 5A Key accessory (air conditioner)
(2) 5A Accessory signal (engine)
(3) 20 A Key B
(4) 20 A Continuous power supply for air conditioner
(5) 20 A Continuous power supply for cab
(6) 5A System operating lamp
(7) 10 A Horn
(8) 20 A Front lamp
(9) 20 A Rear lamp
(10) 15 A 3DMC
(11) 10 A Smart sensor power supply 3
(12) 20 A Smart sensor power supply 1, 2
(13) - -
3-99
Fuse ca-
No. Name of circuit
pacity
(14) 15 A Key accessory (upstream)
(15) 20 A Optional device
Fuse box (2)
Fuse ca-
No. Name of circuit
pacity
(1) 20 A Steering controller power supply
(2) 20 A Air conditioner power supply
(3) 20 A Controller continuous power supply
(4) 30 A Engine controller power supply (24 V)
(5) - -
(6) 30 A Cab main power supply
(7) 20 A DEF heater
(8) - -
(9) - -
(10) 10 A Supply module power supply
Fuse box (3)
Fuse ca-
No. Name of circuit
pacity
(1) 10 A Radio memory
Additional lamp (if equipped), revolving
(2) 20 A
lamp (if equipped)
(3) 20 A 12V converter
Radio, room lamp, cigarette lighter, inter-
(4) 20 A
mittent windshield wiper
Front windshield wiper, rear windshield wip-
(5) 10 A
er
(6) 10 A R.H. and L.H. door wipers
FUSIBLE LINK
NOTICE
When replacing the fusible link, be sure to turn the starting switch to OFF position and, after confirming
that the system operating lamp is not lit, set the battery disconnect switch key to OFF position.
When the starting switch is turned to START position, if the starting motor does not operate, any of the electrical
component in the operator's cab does not work, or the pre-heater does not work, a fusible link built in the wiring
harness is suspected to be disconnected. Open the battery inspection cover on the left side of the machine to
check the fusible links, and replace them.
3-100
Open the battery cover on the left side of the machine and then
open the fusible link case cover, and you see fusible links (1) to
(3).
Fuse ca-
No. Name of circuit
pacity
(1) 80 A Continuous power supply
(2) 120 A Ribbon heater
(3) 120 A Main power supply
REMARK
A fusible link refers to the large-sized fuse installed in the high
current flow portion of the circuit.
It protects electrical components and wiring from burning, in the
same way as an ordinary fuse.
FIRE EXTINGUISHER
(if equipped)
A fire extinguisher is provided at the rear part inside the opera-
tor's cab.
The directions are described on the nameplate affixed to the
fire extinguisher. Carefully read and understand them before-
hand for an emergency.
SHOVEL HOLDER
(Machine with shovel holder)
3-101
This can be used for storing a shovel with a rounded blade.

1. When storing a shovel, fix it with stopper (1) and holder
(2).
2. Tighten the adjustment nut (3) so the shovel does not
move.
BATTERY DISCONNECT SWITCH

k CAUTION
• Do not operate the battery disconnect switch while the engine is running.
The large current generated by the alternator may burn the electric parts and cause a fire.
When operating the battery disconnect switch, always stop the engine.
• If the battery disconnect switch is turned to OFF position, always remove the switch key.
If someone turns the key to ON position carelessly, this is extremely dangerous.
NOTICE
• Keep battery disconnect switch in ON position except the following cases.
• When the machine is stored for a long time (more than a month)
• When repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing fuse, etc.
• Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit. If
the battery disconnect switch is turned to OFF position while the system operating lamp is lit, the
data in the controller will be lost and system abnormality may occur.
• If this switch is turned to OFF position, all the electrical system is cut out and the functions of KOM-
TRAX stop. In addition, the time information of the clock and the radio tuning information may be
lost. In this case, set again. For detail, see “CLOCK ADJUSTMENT (3-72)” and “HANDLING RADIO
(3-216)”.
3-102
Battery disconnect switch (1) is used to cut out the electricity

from the battery.
This is inside the battery inspection cover on the left side of the
machine.
Open rubber cover (2), and battery disconnect switch (1) is
seen.
REMARK
Operate this switch while system operating lamp (3) is OFF.
(O): OFF position

Switch key (1) can be pulled out (and inserted) and the current
from the battery is cut out.
(I): ON position
The current from the battery flows into the circuit.
Before starting the machine, be sure to set the switch to this
position.
SYSTEM OPERATING LAMP

System operating lamp (1) indicates that the controller mount-
ed on the machine is turned ON.
System operating lamp (1) lights up when the controller is
turned ON.
Usually, it goes out in 5 to 6 minutes after the starting switch is
turned to OFF position.
Before operating the battery disconnect switch, check that sys-
tem operating lamp (1) is not lit.
NOTICE
If the battery disconnect switch is turned to OFF position
while the system operating lamp is lit, the data in the con-
troller will be lost and system abnormality may occur.
3-103
REMARK
• Even if the starting switch is in OFF position, the controller may operate. The system operating lamp lights
up in this case, but it is not abnormal.
• After the starting switch has been turned off, the system operating lamp may stay lit for a long time.
In such case, consult your Komatsu distributor.
• While DEF system devices are operating, the system operating lamp lights up to return DEF to the tank.
Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit.
• The system operating lamp may look slightly luminous in the dark even when it is not lit. It is due to the
minute leakage of current and this is not an abnormal phenomenon.
DUST INDICATOR
This device notifies the operator of clogging of air cleaner ele-
ment.
For the cleaning method of the element, see “METHOD FOR
CHECKING, CLEANING AND REPLACING AIR CLEANER
(4-15)”.
HANDLE Komatsu Diesel Particulate Filter (KDPF)

k CAUTION
• Exhaust gas temperature may increase higher than the previous models during the aftertreatment
devices regeneration and the high temperature may last after the completion of regeneration.
Avoid getting near the exhaust pipe outlet and around the aftertreatment devices to prevent being
burnt.
Also, keep combustible materials away from the exhaust pipe outlet and around the aftertreatment
devices to prevent a fire.
• When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to
the regeneration disable to prevent fire hazards due to highly heated exhaust gas during the after-
treatment devices regeneration.
For the setting, see “PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE
SETTING (3-110)”.
KDPF is a device to capture soot in the exhaust gas to purify

the exhaust gas.
If soot is accumulated to a certain level in KDPF, a purification
process to burn the soot is performed automatically to keep the
filtering performance of KDPF high.
This purification process is called the “regeneration”.
If operations which lower the purification function of KDPF con-
tinues for long hours, the regeneration is performed to protect
the KDPF system, regardless of the quantity of the accumulat-
ed soot.
3-104
During the KDPF regeneration, aftertreatment devices regener-

ation pilot lamp (1) lights up on the monitor.
REMARK
Even if aftertreatment devices regeneration pilot lamp (1) lights
up, the machine does not need to be stopped and the work can
be continued, unless the caution lamp is displayed at the cen-
ter of the machine monitor.
The KDPF regeneration is performed automatically. However,
the accumulated soot may not be burnt sufficiently and the fil-
tering function may not be improved under certain operating
conditions.
In that case, KDPF soot accumulation caution lamp (2) lights
up. If this lamp lights up, stop the machine in a safe place and
perform the manual stationary regeneration.
For details of the procedure, see “PROCEDURE FOR MAN-
UAL STATIONARY REGENERATION (3-108)”.
If hydraulic fan reverse operation is performed while the after-
treatment devices regeneration pilot lamp or the KDPF soot ac-
cumulation caution lamp is lit, the accumulated soot may not be
burnt sufficiently and the filtering function may not be improved.
Wait until the aftertreatment devices regeneration pilot lamp or
the KDPF soot accumulation caution lamp goes out, and then
perform hydraulic fan reverse operation.
For the operation to reverse the hydraulic fan rotation, see “MACHINE SETTINGS (3-63)”.
Two types of machine monitor display require the manual stationary regeneration, depending on the level of ur-
gency.
If the parking brake lever and work equipment lock lever are set to LOCK position, the manual stationary regen-
eration may start automatically to protect the KDPF system.
NOTICE
Do not stop engine when the aftertreatment devices regeneration is activated.
When stopping the engine, stop the aftertreatment devices regeneration first according to “PROCE-
DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING (3-110)”, then keep en-
gine running at low idle for approximately 5 minutes, and stop engine.
When the Action level “L03” lights up in red, and the KDPF
soot accumulation caution lamp (2) lights up in red, engine
power deration is activated. To restore engine power, it is
necessary to perform “PROCEDURE FOR MANUAL STA-
TIONARY REGENERATION”.
If soot accumulated in the KDPF exceed the defined level
without performing “PROCEDURE FOR MANUAL STA-
TIONARY REGENERATION”, the Action level “L04” lights
up in red. Stop the machine immediately and ask your Ko-
matsu distributor.
3-105
REMARK
• Soot accumulation level (4) can be checked with the “Af-
tertreatment Devices Regeneration” screen.
Press switch F6 on the standard screen to display “After-
treatment Devices Regeneration” screen of the user menu.
• Since the soot in the filter of KDPF can be burnt by the
high-performance catalyst and high-temperature exhaust
heat, the soot accumulation quantity may decrease even if
the regeneration is not performed, depending on the oper-
ating condition.
• Even when the soot accumulation level is low, the auto-
matic regeneration may be performed and the manual sta-
tionary regeneration may be requested to protect the sys-
tem. In particular, if engine is kept running with no load, the
regeneration frequency may increase, but this is not a fail-
ure.
• Even just after the regeneration is completed, the soot ac-
cumulation level may not be “0”. This is caused by the ac-
cumulated noncombustible material in the exhaust gas and
is not a failure.
• Since noncombustible matter which cannot be burnt by the
regeneration is accumulated in the filter of KDPF, the filter
needs to be cleaned or replaced at regular intervals. See
“METHOD FOR CLEANING KDPF (4-79)”.
• The engine speed or engine sound may change during or
after the regeneration. This is caused by the control for
better regeneration and this is not a failure.
• The smell of the exhaust gas is different from that of the
conventional diesel engine because of the exhaust gas fil-
tering function.
• White smoke may be discharged for a short time just after
the engine is started or during the regeneration in the cold
season, but this is not a failure.
• Komatsu recommends using Komatsu genuine engine oil
for KDPF. If engine oil other than Komatsu genuine oil for
KDPF is used, it may shorten cleaning interval of KDPF fil-
ters, adversely affect the engine such as deteriorated oil
may reduce lubricating function, and it may cause failure.
In addition, the regeneration interval may be shortened
and the fuel consumption may increase. For details of the
genuine oil, see “RECOMMENDED FUEL, COOLANT,
AND LUBRICANT (7-6)”.
• If the mixing ratio of the bio-fuel in the diesel fuel is high,
the regeneration of KDPF may become more frequent.
3-106
When the degree of emergency is low

• If KDPF soot accumulation caution lamp (2) lights up in
yellow (action level (3): “L01”), screen (A) is displayed first.
• The action level goes out 2 seconds later and the screen
changes back to standard screen (B).
• If the parking brake lever and work equipment lock lever
are set to LOCK position, or joystick (steering, directional
and gear shift lever) is set to NEUTRAL position, the
screen changes to “Aftertreatment Devices Regeneration”
screen (C) after 3 seconds only the first time. If the manual
stationary regeneration is not performed, the screen re-
turns to standard screen (B) after 30 seconds.
Then, if the accumulated soot does not decrease, the “Af-
tertreatment Devices Regeneration” screen (C) is dis-
played for 30 seconds every 2 hours.
yellow, stop the machine in a safe place after finishing the
work and perform the manual stationary regeneration.
When the degree of emergency is high

• KDPF soot accumulation caution lamp (2) lights up in red
and the action level “L03” lights up in red (3).
• If the parking brake lever and work equipment lock lever
are set to LOCK position or joystick (steering, directional
and gear shift lever) is set in NEUTRAL, the screen
changes to the “Aftertreatment Devices Regeneration”
screen (C) after 3 seconds only the first time. Then, “After-
treatment Devices Regeneration” screen (C) and standard
screen (D) are automatically displayed alternately accord-
ing to the lever operation, until the manual stationary re-
generation is performed.
red, immediately stop the machine in a safe place and per-
form the manual stationary regeneration.
3-107
PROCEDURE FOR MANUAL STATIONARY REGENERATION

k CAUTION
Exhaust gas temperature may increase higher than the
previous models during aftertreatment devices regenera-
tion. Avoid getting near the exhaust pipe outlet and around
the aftertreatment devices to prevent being burnt. Also,
keep combustible materials away from the exhaust pipe
outlet and around the aftertreatment devices to prevent a
fire.
The manual stationary regeneration can be performed while

KDPF soot accumulation caution lamp (1) is lit.
1. Move the machine to a safe place and stop the machine
with engine running.
2. Check that there is no person or combustible matter
around the machine (particularly in the direction of the ex-
haust gas flow).
3. Set the parking brake lever and work equipment lock lever
to LOCK (L) position.
Unless they are set to LOCK position, the manual station-
ary regeneration cannot be performed.
4. Set the fuel control dial to Low idle (MIN) position.
5. Press switch F6 to display the “Aftertreatment Devices Re-

generation” screen.
6. Select “Manual Stationary Regeneration”, check again that there is no people or combustible material
around the machine, then press switch F6.
If the machine needs to be moved again to secure safety, move it to a safe place and repeat the procedure
from step 1.
3-108
REMARK
After switch F6 is pressed in step 6., the screen shown in
the figure may be displayed. This indicates that the opera-
tions in steps 1 to 4 were not performed correctly or there
is trouble other than KDPF soot accumulation abnormality.
After checking that the engine is running normal, the park-
ing brake lever and work equipment lock lever are in
LOCK position (L) and the fuel control dial is set to Low
idle (MIN) position, repeat the procedure from step 6.
If the manual stationary regeneration still cannot be per-
formed, return to the standard screen, press switch F5 to
check the contents of other occurring troubles, stop the
work and perform inspection and maintenance.
If hydraulic fan reverse operation is performed while the af-
tertreatment devices regeneration pilot lamp or the KDPF
soot accumulation caution lamp is lit, the accumulated soot
may not be burnt sufficiently and the filtering function may
not be improved. Wait until the aftertreatment devices re-
generation pilot lamp or the KDPF soot accumulation cau-
tion lamp goes out, and then perform hydraulic fan reverse
operation.
REMARK
• The explanation of the manual stationary regeneration
is displayed in 3 parts on the machine monitor panel.
When switch F6 is pressed, the regeneration can be
started immediately, regardless of which part is dis-
played. When switch F5 is pressed, the screen returns
• If no machine monitor switch is operated for 30 sec-
onds, the explanation of the manual stationary regen-
eration disappears and the screen returns to the
standard screen. At this time, to display the explana-
tion of the manual stationary regeneration again,
press switch F6 on the standard screen to display the
“Aftertreatment Devices Regeneration” screen.
3-109
7. The screen shown in the figure is displayed during the

manual stationary regeneration.
It may take more than 40 minutes to complete the manual
stationary regeneration. Do not touch any switch on the
screen or operate fuel control dial until the regeneration is
completed and the standard screen appears again.
REMARK
• The progress of the manual stationary regeneration
performed when soot is accumulated can be checked
by the number of lighting lamps of soot accumulation
level (4). The manual stationary regeneration starts at
soot accumulation level “4” or higher and finishes
when all the level lamps go out.
• The time required for the manual stationary regenera-
tion depends on the soot deposition level or the ambi-
ent temperature when it is started. If the regeneration
starts at soot accumulation level “6” or higher, it may
take approximately 2 hours to finish.
• The manual stationary regeneration for protection of
the system may start even when the soot accumula-
tion level is “0” to “3”. In this case, the soot accumula-
tion level may not decrease, but this is not trouble.
The progress is not displayed on the machine monitor
during this regeneration. It is completed in approxi-
mately 10 minutes.
• If the parking brake lever and work equipment lock
lever or the fuel control dial is operated during the
manual stationary regeneration, the regeneration is
stopped automatically. Return the parking brake lever
and work equipment lock lever to LOCK position (L)
and return the fuel control dial to Low idle (MIN) posi-
tion, then repeat the procedure from step 6.
• If the machine needs to be moved during the manual
stationary regeneration, stop the regeneration tempo-
rarily and move the machine, referring to the after-
treatment devices regeneration disable and cancel
procedures described below.
When restarting the manual stationary regeneration,
secure the safety of the machine and around it, then
cancel the regeneration disable.
8. After the manual stationary regeneration is completed, the screen automatically returns to the standard
screen.
PROCEDURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE

SETTING
If there is combustible material around the machine and the active regeneration that increases the exhaust tem-
perature must not be performed, the automatic active aftertreatment devices regeneration can be disabled. Al-
so, the regeneration in progress can be stopped.
3-110
NOTICE
Even if the regeneration is disabled, KDPF soot accumula-
tion caution lamp (1) lights up if soot is accumulated and
the manual stationary regeneration is required. If KDPF
soot accumulation caution lamp lights up, move the ma-
chine to a safe place and perform manual stationary regen-
eration.
If the operation is continued without performing the man-
ual stationary regeneration, it may cause the failure of
KDPF or the engine.
While regeneration is not being performed: Setting for regeneration disable

(When aftertreatment devices regeneration pilot lamp is lit on the standard screen)
1. On the standard screen, press switch F6.
2. Operate switches F1 and F2 to select “Aftertreatment De-

vices Regeneration” menu (C) and display the “Aftertreat-
ment Devices Regeneration” screen.
3. Select “Regeneration Disable” and press switch F6, then

the regeneration function is disabled and the regeneration
cannot be performed.
3-111
REMARK
• When the regeneration is disabled, aftertreatment devices
regeneration disable pilot lamp (2) is lit on the standard
screen.
• The setting of regeneration disable is canceled by turning
starting switch to OFF position. When the automatic regen-
eration needs to be kept disabled, perform the above pro-
cedure each time you start the engine.
• During the regeneration to protect the system, even if the
regeneration disable is set, aftertreatment devices regen-
eration pilot lamp (3) may light up, but this does not indi-
cate abnormality. Also, during the regeneration to protect
the system, the regeneration disable cannot be operated.
• When the regeneration is performed to protect the system,
the exhaust temperature is lower than that of when the re-
generation is performed to burn soot, and is almost the
same level as the normal exhaust gas temperature.
While regeneration is being performed: Regeneration is disabled

(When aftertreatment devices regeneration pilot lamp (3) is lit on the standard screen)
1. When switch F6 is pressed on the standard screen, the
“Aftertreatment Devices Regeneration” screen is dis-
played.
3-112
2. Select “Regeneration Disable” and then press switch F6,

and the regeneration stops.
REMARK
The regeneration performed to protect the system may not
be stopped, but this is not a failure.
PROCEDURE FOR CANCEL OF AFTERTREATMENT DEVICES REGENERATION

DISABLE SETTING
k CAUTION
When canceling the regeneration disable, move the machine to a safe place and check that there is no
person or combustible matter around the machine, and start the cancel operation.
1. When switch F6 is pressed on the standard screen, the

“Aftertreatment Devices Regeneration” screen is dis-
played.
(If the “Aftertreatment Devices Regeneration” screen is not
displayed, display it by operating switches F1 and F2.)
2. Select “Cancel of Regeneration Disable” and press switch

F6, and the regeneration disable is canceled.
If soot accumulation level (4) is lit 3 or more, the regenera-
tion is started automatically.
REMARK
• When performing the cancel of regeneration disable,
set the parking brake lever and work equipment lock
lever to LOCK position and set the fuel control dial to
Low idle (MIN) position, then perform the cancel of re-
generation disable.
• The regeneration disable setting is also canceled by
turning the starting switch to OFF position to stop the
engine.
3-113
Komatsu Closed Crankcase Ventilation (KCCV)

KCCV is a device to clean the gas discharged from the engine
crankcase with the filter element and return it to the engine air
intake system.
NOTICE
• The KCCV filter element needs to be replaced every
2000 hours. For details of replacement, see “METHOD
FOR REPLACING KCCV FILTER ELEMENT (4-70)”.
• If the engine is operated without KCCV filter element
or if a filter element other than the Komatsu genuine
element is used, the engine sucks oil and foreign ma-
terial which can cause a failure. Always install Komat-
su genuine KCCV filter element.
• The filter element cannot be flushed. Never reuse the
filter element since it can cause a performance decre-
ment of engine, and it result in a failure even if it is
cleaned.
HANDLE UREA SCR SYSTEM WARNING

Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless nitro-
gen and water. By spraying DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3)
and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.
The Komatsu Urea SCR System continuously monitors its operation conditions and stores information on inap-
propriate operations including malfunctions. The information is used for system diagnostics and also for Induce-
ment required by the authorities on engine systems that use Urea SCR systems. Inducement is intended for the
operator to take prompt actions to maintain and correct inappropriate behaviors of Urea SCR systems by utiliz-
ing visible and audible alerts, and engine power derate in addition. Alerts in Inducement of the Komatsu Urea
SCR System progresses step by step starting from visual indications on the machine monitor and audible
sounds to engine power derate to avoid getting into unsafe conditions.
The Komatsu Urea System also monitors recurrences of abnormalities of the system. Inducement in the recur-
rences is activated when another abnormality occurs within 40 hours after the first abnormality is fixed.
The Komatsu’s Urea is composed of two major systems, which are the DEF system and the SCR catalyst Ass’y.
3-114
DEF is supplied from DEF system into the exhaust system.

DEF system consist of DEF tank (1), DEF hose (2), DEF pump
(3), and DEF injector (4). SCR Ass’y is indicated by (5).
In the event that indications of potential degradation of nitrogen
oxides conversion efficiency are detected, the active regenera-
tion is triggered to rejuvenate Urea SCR system even if the
amount of soot accumulated in the KDPF has not reached to
the regeneration thresholds.
For details of Aftertreatment Devices Regeneration, see “HAN-
DLE Komatsu Diesel Particulate Filter (KDPF) (3-104)”.
k WARNING
Fill ONLY DEF into DEF tank. Foreign material in the DEF
system or urea deposits caused by evaporation may hin-
der operation of the devices.
NOTICE
• Foreign materials in the DEF system or urea deposits
caused by precipitation of urea may hinder operation
of the devices.
• Do not disassemble any devices of the DEF System
other than the filter for change. Do not modify any de-
vices of the DEF System.
• Paint may cause deterioration of the devices. When
painting the surrounding areas, take care not to get
any paint on the injector and the supply pump.
• Always use DEF that conforms to the quality standard.
If any additional additive agents or water is mixed in
DEF and that mixture is used, the devices will not
function properly, and conformance to the exhaust gas
regulations will be lost. In addition, it may cause fail-
ures in the engine system. If DEF out of the standard
is filled or used by mistake, contact your Komatsu dis-
tributor.
About the operation of Urea SCR system

The Urea SCR System automatically starts operating as soon as the engine is started.
Even after the engine starting switch is turned to the OFF position, the devices will still be in operation for sever-
al minutes to purge any DEF in the lines, the injector and the supply pump back to the DEF tank. It does not
indicate any abnormality. When DEF has been returned to the tank, the devices stop.
Do not turn OFF the battery disconnect switch while the devices are still in operation. When the devices com-
plete their shutdown process, the system operating lamp will go out, and the battery disconnect switch may be
disconnected.
About the operation in cold weather
DEF freezes at –11 °C.
3-115
Urea SCR system is equipped with a heating system to thaw frozen DEF once it is frozen, for example, during
parking and to prevent DEF from freezing during operation.
In case DEF freezes during parking, once the engine starts running the heating system automatically starts pro-
viding heat to thaw frozen DEF. The pump and the injector start working only after a proper amount of DEF is
thawed. This may be noticed as a delay in the start of functioning of the pump and the injector.
The heating system is also activated automatically during operation to prevent DEF from freezing whenever the
ambient temperature drops below a certain threshold where DEF in the system may freeze. In the event that the
ambient temperature drops further than a temperature where the heating system is capable of maintaining fluidi-
ty of DEF, the DEF system automatically starts purging the remaining DEF back to the tank and stops pumping
and injection while heating continues. Once the ambient temperature rises above a temperature where DEF
system becomes functional, it resumes operation automatically.
Short duration of white plume given off from the tail pipe may be visible at and shortly after engine start-up in
cold weather, but this is not malfunction.
Inducement strategy when the DEF tank Level becomes low
When the amount of DEF fluid in the tank goes low, the Inducement strategy will be activated.
If Inducement starts, add DEF to the DEF tank immediately.
The DEF level caution lamp (1) on the monitor lights up, the audible alert starts, and the Action level is dis-
played, and Inducement strategy is activated. Inducement strategy includes engine output deration, speed limi-
tation, or other warning actions intend to prompt the operator to maintain or repair SCR system.
The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low level Inducement and
Severe Inducement.
The DEF level caution lamp (1) on the machine monitor will
light up, audible alert will start, then Action level will be dis-
played on the machine monitor, and engine power will be derat-
ed in steps.
In Action Level “L03 (Low level Inducement)” and “L04 (Severe
Inducement)” engine power will be derated. When Action Level
“03” or “04” is displayed, move the machine to a safe place and
add DEF.
The content of the warning can be checked on the “SCR Infor-
mation” screen of the user menu.
Perform the following procedure.
Press F6 on the standard screen to display the “SCR Informa-
tion” screen of the user menu.
If either the parking brake lever and work equipment lock lever
are set to LOCK position or the joystick (steering, directional
and gear shift lever) is in NEUTRAL position for over 3 sec-
onds, “SCR Information” screen of the user menu will pop up
automatically while the Urea SCR system is in Inducement.
“SCR Information” screen displays the DEF level caution lamp

(1), the DEF level gauge (2), information on the Urea SCR Sys-
tem condition (3), and the current status of Inducement (4).
If Inducement starts, stop the machine in a safe place and add
DEF.
Once the audible alert starts, “The buzzer cancel switch” does
not work unless DEF is added.
3-116
• Warning:
2 gradations of the DEF level gauge light up in the red
range.
The DEF level caution lamp (1) lights up in red.
No audible alert.
No Action level is displayed.
Press F6 to display the “SCR Information” screen.
Inducement status (4): “1 DEF low level warning appears.”

Add DEF to the DEF tank immediately.
• Continuous Warning:
The audible alert sounds in repetition of “three beeps and
a pause”.
2 gradations of the DEF level gauge light up in the red
range.
DEF level caution lamp (1) lights up in red.
No Action level is displayed.
Inducement status (4): “2 Without treatment, engine power

will be derated.”
• Low level Inducement:

The audible alert sounds in short and sharp beeps.
1 gradation of the DEF level gauge light up in red.
Action Level “L03” is displayed in red (5).
3-117
Inducement status (4): “3 Engine power is under deration.”

• Severe Inducement:
The audible alert sounds in continuous beep.
No gradation of the DEF level gauge lights up .
The Action level “L04” is displayed in red (5).
Inducement status (4): “4 Engine power is under heavy de-

ration.”
Engine power can be restored temporarily from power derate. This engine power restoration works only
when the Inducement status is “Severe Inducement”and relieves back temporarily to the power deration of
the “Low level Inducement”. The operator can restore engine power through the machine monitor. For the
engine power restoration procedure, refer to the section of “Temporary Restoration from Inducement” in this
manual. Once in “Severe Inducement” and it becomes necessary to restore engine power, use the engine
power restoration function to move the machine to a safe place and add DEF.
Inducement strategy when abnormalities are detected in the Urea SCR System
devices (Except abnormalities in the KDPF and the EGR system)
If any abnormality is detected in the DEF quality or in the Urea SCR system, the Inducement strategy is activa-
ted.
The inducement strategy progresses in 4 levels, “Warning”,
“Continuous Warning”, “Low level Inducement” and “Severe In-
ducement”. The Inducement strategy includes visual alert by
the DEF caution lamp, the KDPF system caution lamp or the
Engine system caution lamp (1), and Action Level displayed on
the machine monitor (2), and the audible alert by a buzzer and
stepwise engine power deration that advances to speed limita-
tion to low idle. Engine power deration starts with Action Level
“L03 (Low level Inducement)” and advances to further deration
when “L04 (Severe Inducement)” is displayed. If “L03” is dis-
played, move the machine to a safe place and contact your Ko-
matsu distributor.
The content of the warning can be checked on the “SCR Information” screen of the user menu.
3-118

“SCR Information” screen displays remaining time to the next

Inducement status in the column (5), and information on the
Urea SCR System condition (3), and the current status of In-
ducement (4).
• Warning:
No audible alert.
The DEF system caution lamp (1) lights up in yellow.
Note: Action Level “L01” once shows up in yellow on the
machine monitor (2) for two seconds and goes out.
“SCR Information” screen message (4): “1 Please inspect

and maintain SCR system.”
Move the machine to the safe place and contact your Ko-
matsu Distributor.
If operation continues for 5 hours after “Warning” started
without taking any actions instructed by the Action Level
table, Inducement advances to “Continuous Warning”.
a pause”.
If operation continues for 5 hour after “Warning” started
3-119
“SCR Information” screen message (4): “2 Without treat-

ment, engine power will be derated.”
matsu Distributor.
The duration of “Continuous Warning” is 5 hours. The re-
maining time (Hours and Minutes) to “Low level Induce-
ment” is displayed in the column (5) of the “SCR Informa-
tion” screen.
In “Low level Inducement”, engine performance will be de-
rated.

The DEF system caution lamp (1) lights up in red.
Action level “L03” lights up in red at action level display (2)
and stays on.
“SCR Information” screen message (4): “3 Engine power is

under deration.”
Due to the engine power deration, capability of the ma-
chine will be limited.
matsu Distributor.
The duration of “Low level Inducement” is 10 hours. The
remaining time (Hours and Minutes) to “Severe Induce-
ment” is displayed in the column (5) of the “SCR Informa-
tion” screen.
In “Severe Inducement”, engine power will be derated fur-
ther.
The DEF system caution lamp (1) lights up in red.
Action level “L04” lights up in red (2).

under heavy deration.”
Due to the further deration of engine power, capability the
machine will be limited further.
“Severe Inducement” is the final status of Inducement.
Unless all the “SCR system” abnormalities are corrected,
engine performance will be kept derated.
3-120
Engine power can be restored temporarily from power derate. If Inducement advances to “Severe Induce-
ment” and it becomes necessary to restore engine power, use the engine power restoration function to
move the machine to a safe place and contact your Komatsu distributor. This engine power restoration
works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power
deration of “Low level Inducement”. The operator can restore engine power through the machine monitor.
For the engine power restoration procedure, refer to the section of “Temporary Restoration from Induce-
ment” in this manual.
Inducement strategy when abnormality is found in the KDPF System by the
Urea SCR system
If any abnormality is detected in the KDPF System through the Urea SCR system, the Inducement strategy is
activated.
“Continuous Warning”, “Low level Inducement”, and “Severe In-
the KDPF System caution lamp (1), DEF system caution lamp
(2), and Action Level displayed on the machine monitor (3), au-
dible alert by a buzzer and stepwise engine power deration that
advances to speed limitation to low idle. Engine power deration
starts with Action Level “L03 (Warning, Continuous Warning
and Low level Inducement)” and advances to further deration
when “L04 (Severe Inducement)” is displayed. Once the sys-
tem advances to “Severe Inducement”, the engine power will
be further derated. If “L03” is displayed, move the machine to a
safe place and contact your Komatsu distributor.

ducement (5).
3-121
• Warning:
The KDPF system caution lamp (1) lights up in red.
The action level “L03” lights up in red at action level dis-
play (3).

Engine power is derated.
matsu Distributor.
a pause”.
play (3).

matsu Distributor.
The duration time of “Continuous Warning” is 5 hour. The
remaining time (Minutes) till the next Inducement status of
“Low level Inducement” is displayed in the column (6) of
“SCR Information” screen.
In “Low level Inducement”, engine power will be derated.

DEF system caution lamp (2) lights up in red.
play (3).
3-122

under deration.”
Due to the reduction of engine power, the machine normal
operation will be limited.
The duration time of “Low level Inducement” is 10 hour.
The remaining time (Minutes) to “Severe Inducement” is
displayed in the column (6) of “SCR Information” screen.
ther.
matsu Distributor.
Action level “L04” lights up in red at action level display (3).
If the restoration of the KDPF system abnormality is not
performed, engine performance will kept be derated.
when the Inducement status is “Severe Inducement” and Engine power can be restored temporarily from
power derate. This engine power restoration works only when the Inducement status is “Severe Induce-
ment” and relieves back temporarily to the power deration of “Low level Inducement”. The operator can re-
store engine power through the machine monitor. For the engine power restoration procedure, refer to the
section of “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In-
ducement” and it becomes necessary to restore engine power, use the engine power restoration function to
move the machine to a safe place and contact your Komatsu distributor.
Inducement strategy when abnormality is found in the EGR Valve System by the
Urea SCR system
If any abnormality is detected in the EGR Valve System through the Urea SCR system, the Inducement strategy
is activated.
“Continuous Warning”, “Low level Inducement”, and “Severe In-
the Engine system caution lamp (1), DEF system caution lamp
(2), and Action Level displayed on the machine monitor (3), au-
dible alert by a buzzer and stepwise engine power deration that
advances to speed limitation to low idle. Engine power deration
starts with Action Level “L03 (Warning, Continuous Warning
and Low level Inducement)” and advances to further deration
when “L04 (Severe Inducement)” is displayed. Once the sys-
tem advances to “Severe Inducement”, the engine power will
be further derated. If “L03” is displayed, move the machine to a
safe place and contact your Komatsu distributor.
3-123


ducement (5).
• Warning:
The Engine system caution lamp (1) lights up in red.
play (3).

Engine power is derated.
matsu Distributor.
a pause”.
play (3).
3-124

matsu Distributor.
The duration time of “Continuous Warning” is 5 hour. The
remaining time (Minutes) till the next Inducement status of
“Low level Inducement” is displayed in the column (6) of
“SCR Information” screen.
In “Low level Inducement”, engine power will be derated.

play (3).

under deration.”
Due to the reduction of engine power, the machine normal
operation will be limited.
The duration time of “Low level Inducement” is 10 hour.
The remaining time (Minutes) to “Severe Inducement” is
displayed in the column (6) of “SCR Information” screen.
ther.
matsu Distributor.
Action level “L04” lights up in red at action level display (3).

If the restoration of the KDPF system abnormality is not
performed, engine performance will kept be derated.
when the Inducement status is “Severe Inducement” and Engine power can be restored temporarily from
3-125
power derate. This engine power restoration works only when the Inducement status is “Severe Induce-
ment” and relieves back temporarily to the power deration of “Low level Inducement”. The operator can re-
store engine power through the machine monitor. For the engine power restoration procedure, refer to the
section of “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In-
ducement” and it becomes necessary to restore engine power, use the engine power restoration function to
move the machine to a safe place and contact your Komatsu distributor.
Temporary Restoration from Inducement
Temporary Restoration from Inducement is the one of the Inducement strategies allowed to be included in Urea
SCR systems.
In case the Urea SCR system advances to “Severe Inducement”, engine power is derated heavily. This may
cause difficulties of moving the machine to a safe place for adding DEF or troubleshooting and correcting abnor-
malities of the Urea SCR system. For temporary remedies from these difficulties the operator can restore engine
power for a short time to the deration of “Low level Inducement” through the machine monitor. Note that “Tempo-
rary Restoration from Inducement” does not regain full engine power.
“Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe In-
ducement”. The maximum duration is limited to 30 minutes in each restoration operation, and only 3 operations
are allowed unless all the abnormalities of the Urea SCR system are corrected.
If the system advances to “Severe Inducement”, utilize “Temporary Restoration from Inducement” immediately.
Procedure to activate “Temporary Restoration from Inducement”.
1. Press F6 to display the “SCR Information” screen when
the Standard screen is on, only when the Urea SCR sys-
tem is in “Severe Inducement”.
2. Press F6 to display the menu windows popping up in the

bottom half of the “SCR Information”.
The menu windows popping up in the bottom half of the
“SCR Information” screen alternate every 15 seconds as
shown in the graphics A and B.
3-126
3. Press F6 while the pop-up menu screen B is displayed.

The “Engine power Recovery” window pops up.
If F6 is not pressed for 30 seconds, “ Standard Screen” will
be displayed, and start again by pressing F6.
The remaining number of operations of Temporary Resto-
ration from inducement is displayed in the column (1) of
the pop-up menu window B.
4. Press F6 while the “Engine power Recovery” window is

displayed.
Temporary Restoration from Inducement is activated and
engine power deration is relieved to the deration of “Low
level Inducement” for the maximum of 30 minutes.
The remaining time (minutes/seconds) of “Temporary Re-

storation from Inducement” is displayed in the column (2)
on the “SCR Information” screen.
If it is decided NOT to activate “Temporary Restoration from Inducement” after having progressed to the “Engine
Power Recovery” window, follow the steps explained in this section.
To deactivate “Temporary Restoration from Inducement” function.
1. Press F5 while the “Engine Power Recovery” window is displayed.
3-127
This procedure is split from procedure 4 in “Temporary Re-

storation from Inducement”.
“SCR Information” screen is displayed.
2. Move any operating lever to display “Standard Screen”.

“Temporary Restoration from Inducement” is deactivated.
Inducement Strategy for abnormalities recurrences within 40 hours

The Urea SCR system continuously monitors its operation conditions and stores information on inappropriate
operations including malfunctions. The stored information is utilized to monitor recurrences of abnormalities,
“Abnormality Recurrence Counter”. “Abnormality Recurrence Counter” is required by the authorities. The recur-
rence monitoring spans 40 hours and it monitors the abnormalities that trigger Inducement other than the
amount of DEF in the tank.
If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were corrected,
regardless of the level of the previous Inducement and whether the new abnormality/abnormalities is the same
as the previous ones or not, it is judged as a recurrence.
If a recurrence occurs, “Severe Inducement” will be activated.
Inducement in the recurrence resumes counting time at the time when the previous abnormalities were correc-
ted if the previous Inducement is in “ Warning” or “Continuous Warning” or “Low level Inducement”. The alerts
resume the previous Inducement.
If this occurs, utilize “Temporary Restoration from Inducement” and move to the machine to a safe place, and
contact your Komatsu distributor.
The maximum duration of power restoration is 30 minutes and 3 operations are allowed.
To activate “Temporary Restoration from Inducement”, refer to the “Temporary Restoration from Inducement”
section in this manual.
3-128
DEF FILTER
DEF filter is an filter element to clean DEF sucked from the
DEF tank by DEF pump, and to supply it to DEF injector.
NOTICE
• The DEF filter element needs to be replaced every
2000 hours. For details of replacement, see “METHOD
FOR REPLACING DEF FILTER (4-73)”.
• If the machine is operated without DEF filter attached,
or with the filter other than Komatsu genuine parts,
foreign materials may enter into DEF pump and DEF
injector which will cause failure of the machine. Never
operate the machine without DEF filter attached, nor
use the filter other than Komatsu genuine parts.
• DEF filter cannot be flushed. Flushing or regenerating
of it will degrade the performance of DEF filter, and will
contaminate DEF pump and DEF injector which will
cause the failure of the machine. Never reuse the DEF
filter.
KOMTRAX
KOMTRAX equipment may not be mounted on machines for some countries or regions.
OUTLINE OF KOMTRAX
KOMTRAX is a system that remote-controls machines equipped with the KOMTRAX device by using satellite
communication or portable radio communication.
Each customer can check the machine information of various types (machine position information, etc.) in the
web screen of a personal computer
The machine information you can check with KOMTRAX includes the following; “Machine position”, “service me-
ter”, “working hours”, “fuel consumption”.
Your Komatsu distributor uses the above machine information for supply of service to the customers, improve-
ment of our products and service, etc.
If you want to use KOMTRAX, you are required to register to your Komatsu distributor.
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k WARNING
• Never disassemble, repair, modify, or move the communications terminal, antenna, or cables. This
may cause failure or fire on the KOMTRAX equipment or the machine itself. (Your Komatsu distribu-
tor will perform removal and installation of KOMTRAX.)
• For anyone wearing a pacemaker, make sure that the communications antenna is at least 22 cm
from the pacemaker. The radio waves may have an adverse effect on the operation of the pacemak-
er.
• Near the blasting jobsite, there may be a danger of unexpected explosion due to use of interactive
wireless communication device of KOMTRAX and resulting serious personal injury or death. Make
sure to operate the machine away from the blasting jobsite.
If you have to operate the machine within 12 m from the blasting jobsite or the remote-controlled
blasting device, the power supply cable of KOMTRAX must be disconnected in advance. If you want
to do this, ask your Komatsu distributor for disconnecting power supply cable of KOMTRAX.
Also, if there are any requirements or regulations of the territory or country where the machine
equipped with this device is used, such requirements or regulations have a priority than this warn-
ing.
When checking for compliance with regulations, refer to the following KOMTRAX equipment satel-
lite communication specifications.
Rated transmit power: 5 to 10 W
Transmit frequency:148 to 150 MHz
PRECAUTIONS FOR USING KOMTRAX

• Even when the key in the starting switch of the KOMTRAX system is at OFF position, a small amount of
electric power is consumed.
It is recommended to run the engine periodically to charge the battery. When storing the machine for a long
period, see “PRECAUTIONS FOR LONG-TERM STORAGE (3-232)”.
• When using the battery disconnect switch, turn the starting switch to OFF position and turn the battery dis-
connect switch key to OFF position. Then, remove the key.
When the battery disconnect switch is turned to OFF position, it is possible to prevent power consumption
of the battery, but the functions of KOMTRAX stop at the same time.
For operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-102)”.
• Contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof.
REMARK
The KOMTRAX device uses wireless communications, so it cannot be used inside tunnels, underground, inside
buildings, or in mountain areas where radio waves cannot be received. Even when the machine is outside, it
cannot be used in areas where the radio signal is weak or in areas outside the wireless communication service
area.
OBSERVANCE OF THE APPLICABLE LAWS AND REGULATIONS, EXEMPTION

The KOMTRAX equipment is a wireless device using radio waves, so it is necessary to obtain authorization and
conform to the laws of the country or territory where the machine equipped with KOMTRAX is being used. Ob-
serve the applicable laws and regulations of the country or region in which the machine is used.
Always contact your Komatsu distributor before exporting this machine equipped with KOMTRAX or using it in a
foreign country.
The KOMTRAX may already have been registered and used if the machine is purchased as second-hand. For
the registration and usage records of KOMTRAX, consult your Komatsu distributor.
If the machine has been lent out by the customer, the borrower or another third party may have been using the
KOMTRAX. Confirm with the lessor about using condition of KOMTRAX.
Komatsu may suspend KOMTRAX communication in the following cases.
• When Komatsu judges that KOMTRAX is used by an unregistered customer.
• When Komatsu judges that KOMTRAX is used in a country or region where its use is not authorized.
3-130
• In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com-
munication.
If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any
resulting impacts or damages.
NOTICE
For more information on KOMTRAX and the Radio Equipment Directive (2014/53/EU), please refer to the
Komatsu Europe website.
https://www.komatsu.eu/Komtrax-Radio-Equipment-Directive
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MACHINE OPERATIONS AND CONTROLS OPERATION
MACHINE OPERATIONS AND CONTROLS

METHOD FOR WALK-AROUND CHECK
Before starting the engine, walk around the machine and look at the underside of chassis for anything unusual
like loose bolts and nuts, leakage of fuel, oil and coolant. Also check the condition of the work equipment and
the hydraulic system.
Check also for loose wiring, play, and accumulation of dust in places that get very hot and are exposed to ex-
tremely high temperatures.
k WARNING
• Any combustible materials accumulated around the exhaust pipe, aftertreatment devices, turbo-
charger, or other high temperature engine parts or the battery, and leakage of fuel or oil will cause
the machine to catch fire.
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.
• Do not get on or off the machine from the rear. Since the floor is slippery and not seen from the
operator seat, it is dangerous to get on or off there. Always use the handrail and step at the side
when getting on or off the machine.
If the machine is inclining, make it level before checking.

Always perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage, and hoses.
Check for cracks, excessive wear, play in work equipment, cylinders, linkage, and hoses. If any problem is
found, repair it.
2. Remove dirt and debris from around the engine, battery, and radiator.
Check for dirt accumulated around the engine and radiator. Also check for combustible materials (dry
leaves, twigs, etc.) around the battery, exhaust pipe, aftertreatment devices, turbocharger, or other high
temperature engine parts. If any dirt or combustible materials are found, remove them.
3. Check around the engine for leakage of coolant, oil, and air.
Check for oil leakage from the engine, coolant leakage from the cooling system, and air leakage from the
air intake system. If any problem is found, repair it.
4. Check the fuel line for leakage.
Check for leakage of fuel or damage to the hoses and tubes. If any problem is found, repair it.
5. Remove dirt and check DEF line for leakage.
Check for dirt accumulated around the DEF tank and clean blue DEF tank filler cap and surrounding area.
Check DEF tank, pump, injector, and hoses and their connections for leakage. If any problem is found, ask
your Komatsu distributor for repair.
6. Check the power train case, final drive case, hydraulic tank, hoses, and joints for oil leakage.
Check for oil leakage. If any problem is found, repair the place where the oil is leaking.
Check for oil leakage from the undercover. Check the ground for traces of oil leakage.
7. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers.
If any problem is found, repair it.
8. Check the handrails and steps for problems and check the bolts for looseness.
If any problem is found, repair it. Tighten any loose bolts.
9. Check the gauges and monitor for problem.
Check for problem in the gauges and monitor in the operator's cab. If any problem is found, ask your Ko-
matsu distributor for repair. Clean off any dirt on the surface.
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OPERATION MACHINE OPERATIONS AND CONTROLS
REMARK
When cleaning the stains deposited on the monitor surface such as dusts, brush them off with a clean, soft
and dry cloth.
For sticky dirt such as oil, remove it with glass cleaner for family use on the market (weakly acid to weakly
alkaline, containing no abrasive), and then finish-wipe with a clean, soft, and dry cloth.
10. Check the panels, gauges, and lamps for breakage, and check the bolt for loosening.
Check the panels, gauges, and lamps for abnormality, and replace the failed parts, if any. Clean off any dirt
on the surface.
11. Check and clean rearview mirrors
Check for damage to the rearview mirrors. If it is damaged, repair it. Clean the surfaces of the mirrors and
adjust the angle according to “METHOD FOR ADJUSTING MIRRORS”.
12. Check the seat belt and mounting hardware.
Check the seat belt and mounting hardware for any abnormality. If any damage is found, ask your Komatsu
distributor to replace it with new one.
13. Check and clean the camera (Machine with camera)
When cleaning the camera, wipe off any dirt with soft cloth.
When cleaning camera, if you stand on an unstable place, or take an unstable posture, you may fall and be
injured. Put proper stepladder or step on the level and firm ground, and clean the camera in secure posture.
Check the camera for any abnormality. If any problem is found, ask your Komatsu distributor for repair.
14. Remove dirt from around the aftertreatment devices.
Check the space around the aftertreatment devices for accumulated dirt and combustible materials (dry
leaves and twigs). If any dirt or combustible materials are found, remove them.
15. Check around the aftertreatment devices for exhaust gas leakage.
Check the pipe between the KDPF and turbocharger and also the KDPF connection for leakage of exhaust
gas (and deposition of soot). If any problem is found, ask your Komatsu distributor for repair.
16. Check around SCR for exhaust gas leakage.
Check the pipe connecting KDPF to SCR and also SCR connection for leakage of exhaust gas (and depo-
sition of urea, etc.) If any problem is found, ask your Komatsu distributor for repair.
17. Check KCCV piping for oil leakage.
Check the pipings (3 pieces) which are connecting the KCCV filter to the turbocharger, oil pan, and cylinder
head for ooze of oil If any problem is found, ask your Komatsu distributor for repair.
METHOD FOR CHECKING BEFORE STARTING

Always check the items in this section before starting the engine each day.
METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK

Perform this procedure before operating the machine.
Prepare a container to catch drained fuel.
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1. Open cover (1).

2. Prepare a container to catch the drained fuel.
3. Turn drain valve (2) at the bottom of the tank to OPEN po-
sition (O).
The sediment and water accumulated in the bottom are
drained together.
Be careful not to get fuel on yourself.
4. When clean fuel flows out, turn drain valve (2) to CLOSE
position (C).
METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDI-

MENT
The water separator serves to separate water mixed in the fuel.
Prepare a container to catch the water and sediment.
1. Open the battery inspection cover on the left side of the
machine.
The water separator is in one piece with fuel filter (1) and
located in the lower part.
2. Check the water level and amount of sediment through
transparent cup (2).
3. If water or sediment is accumulated, drain them.
1) Pull out drain hose (3) and take its end out of the ma-
chine.
2) Prepare a container to catch the water and sediment
at the end of drain hose (3).
3) Loosen plug (4) and drain the water.
4) When fuel starts draining from drain hose (3), tighten plug (4) immediately.
5) Return drain hose (3) to its original position.
Tightening torque: 0.2 to 0.45 Nm {0.02 to 0.046 kgm}
METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL

k WARNING
• When the oil filler cap is removed, oil may spout out. After stopping the engine, wait for the oil tem-
perature to go down, turn the cap slowly to release the internal pressure, then remove the cap with
care.
• If hydraulic oil has been added to above mark H, stop the engine and wait for the hydraulic oil to
cool down. Then remove cover (1), loosen drain plug (2), and drain the excess oil.
3-134
NOTICE
Do not add oil above H line. It may damage the oil circuit
and cause the oil to spurt out.
1. Place the machine on a level ground and lower the work equipment to the ground.
If the machine is inclining, make it level.
2. Stop the engine.
3. After approximately 5 minutes, check the oil level with the
sight gauge.
• When the oil level is between marks H and L on sight
gauge (G)
The oil level is proper.
• When the oil level is below mark L
The oil is insufficient. Add hydraulic oil through oil filler
port (F).
4. After adding the hydraulic oil, tighten the cap of oil filler
port (F) securely.
METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT

k WARNING
• Do not open the radiator cap unless necessary. When checking the coolant level, check the sub-
tank when the engine is cold.
• Do not remove the reservoir tank cap while the radiator coolant temperature is high. Boiling coolant
may spurt out. After the coolant temperature goes down, turn the cap slowly to release the pres-
sure, then remove it.
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1. Open reservoir tank inspection cover (1) on the right side

of the machine.
2. Check that the coolant level is between FULL and LOW

marks of reservoir tank (2).
• When the coolant level is between FULL and LOW
marks
The coolant level is proper. Close reservoir tank in-
spection cover (1).
• When the coolant level is below LOW mark
The coolant is insufficient. Add coolant.
REMARK
The coolant may overflow from the reservoir tank
drain hose. This is no problem. It occurs because too
much coolant has been added.
3. After refilling with coolant, tighten the cap securely.
4. Check reservoir tank (2) for abnormality.
If reservoir tank (2) is empty, leakage of coolant should be suspected.
5. If reservoir tank (2) has abnormality, repair it immediately.
6. Check the coolant level in the radiator.
7. If the coolant level is low, add Non-Amine Engine Coolant (AF-NAC) of the same density as Non-Amine
Engine Coolant (AF-NAC) in the radiator, and then add it to reservoir tank (2).
For detail, see “METHOD FOR CLEANING INSIDE OF COOLING SYSTEM (4-19)”.
8. After adding the coolant, close reservoir tank inspection cover (1).
METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL
k WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until they have cooled down before starting the work.
Check the oil level either before engine start or at least 15 minutes after the engine stops.
When the ambient temperature is low, water or emulsified matter may stick to the dipstick, oil filler cap, etc. or
the drained oil may be milky white because of water vapor in the blowby gas. However, if the coolant level is
normal, it is not a problem.
Prepare a container to catch drained oil.
1. Open the engine side cover on the left side of the machine.
3-136
2. Open the cap of oil filler port (F).

3. Pull out dipstick (G) and wipe off the oil with a cloth.
4. Insert dipstick (G) fully into the dipstick pipe and pull it out.
5. Check if the oil is sticking up to between marks H and L on

dipstick (G).
• When the oil level is between marks H and L
• When the oil level is below mark L
The oil is insufficient. Add oil through oil filler port (F).
• When the oil level is above mark H
The oil level is too high. Adjust the oil to a proper level
according to the following procedure.
1) Remove cover (1) on the underside of the machine.
2) Take the end of hose (2) out of the inspection window.

3) Loosen drain plug (P) to drain excessive oil.
When draining the engine oil, put a container to catch
the oil under hose (2).
4) Check the oil level again.
6. After the oil is adjusted to a proper level, insert dipstick (G)
fully into the dipstick pipe again.
7. Tighten the cap of oil filler port (F) securely.
8. Close the engine side cover.
METHOD FOR CHECKING OIL LEVEL IN POWER TRAIN CASE AND ADDING OIL
k WARNING
Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Check the oil level either before engine start or at least 15 minutes after the engine stops.
3-137
1. Open the small cover at the top of the right side of the ma-
chine.
2. Pull out dipstick (G) and wipe off the oil with a cloth.
3. Insert dipstick (G) fully into the dipstick pipe and pull it out.
4. Check if the oil is sticking up to between marks H and L on

dipstick (G).
• When the oil level is between marks H and L, it is
proper.
• If the oil level is below mark L, add oil through oil filler
port (F).
• If the oil level is higher than mark H, decrease it to a
proper level according to the following procedure.
1) Remove cover (1) on the lower rear side of the ma-

chine.
2) Place an oil container to catch oil under drain plug (P).

3) Loosen drain plug (P) to drain excessive oil.
4) Check the oil level again.
5. After the oil is adjusted to a proper level, insert dipstick (G)
fully into the dipstick pipe again.
6. Close the small cover at the top of the right side of the ma-
chine.
METHOD FOR CHECKING DUST INDICATOR

1. Open the reservoir tank inspection cover on the right side of the machine.
3-138
2. Check if the inside yellow piston of dust indicator (1) is lap-

ped over the peripheral red zone.
3. If the yellow piston is lapped over the red zone, clean or
replace the element immediately.
For the cleaning method of the element, see “METHOD
FOR CHECKING, CLEANING AND REPLACING AIR
CLEANER (4-15)”.
REMARK
Also, clean or replace the air cleaner element when the air
cleaner clogging caution lamp lights up.
4. After checking, cleaning, and replacing, push the button of
dust indicator (1).
The yellow piston returns.
METHOD FOR CHECKING BRAKE PEDAL TRAVEL

k WARNING
If the brake pedal stroke is not between 60 to 80 mm (below 60 mm or over 80 mm ), the brake and steer-
ing force is too strong or insufficient. If the stroke is 81 mm or longer, adjust it.
1. Depress the brake pedal fully.

2. Check that the distance of stroke (A) at the center of the
pedal is 60 to 80 mm .
When it exceeds 81 mm or the brake force is insufficient,
ask your Komatsu distributor for adjustment.
METHOD FOR CHECKING ELECTRIC WIRING

k CAUTION
• If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring,
promptly ask your Komatsu distributor to locate the cause of it and to perform the repair.
• Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged
with dirt or dust, wash the battery cap with water to clear the vent hole.
NOTICE
In particular, inspect the wiring of “battery”, “starting motor”, and “alternator” with care.
Perform the following inspection.
• Perform inspection to confirm that the fuses have no defect and their capacity is proper.
3-139
• Perform inspection to confirm that there is no disconnection or trace of short-circuiting in the electric wiring
and no damage to the coating.
• Perform inspection to confirm that there is no loose terminals, and tighten any loose parts if found.
• Always check if there is any accumulation of combustible material around the battery, and remove such
combustible material.
METHOD FOR CHECKING FUEL LEVEL, ADDING FUEL

k WARNING
When adding fuel, never spill the fuel or let it overflow. It may cause a fire.
If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or
sand.
Fuel is highly flammable and dangerous. Do not bring any open flame close.
When performing operations on slopes, to prevent the engine from sucking in air, pay careful attention to the
amount of fuel remaining in the tank.
1. Turn the starting switch to ON position (B).
2. Check the remaining level by fuel gauge (G) on the ma-

chine monitor.
3. After checking, turn the starting switch back to OFF posi-
tion.
4. If the fuel level is low, add fuel through fuel filler port (F).
Fuel tank capacity: 415 ℓ
5. After adding, tighten the fuel filler cap securely.
3-140
METHOD FOR CHECKING DEF LEVEL, ADDING DEF

k WARNING
• Do not put fluid other than DEF into DEF tank.
• When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face
away from the filler port during opening or refilling.
• Foreign materials in the DEF system or urea deposits caused by precipitation of urea may hinder
operation of the devices. Before removing the filler cap, wipe off the dirt from around the filler port.
Before inserting the filler nozzle into the filler port, wipe off dirt from it.
• If DEF is spilled, immediately wipe and wash the area with water. If spilled DEF is left unattended
and the area is not washed and cleaned, it can cause corrosion to the contaminated area and emit
toxic gas.
k CAUTION
• BIB container (10 ℓ) weighs 11 kg.
Before putting it on the DEF tank filler port cover, put BIB container on the rear of the track first.
Then, climb on the top of the track from the front of machine, and move BIB container to the top of
the DEF tank filler port cover.
• The DEF supply hose is installed to this machine.
The hose is in a plastic bag. After using the hose, put it into the bag and close it to store.
It prevents dust from sticking to the hose. In addition, it also prevents the machine from getting
dirty and being corroded by the fluid from the hose.
• When the DEF supply hose gets dirty, wash it in distilled water, deionized water or DEF.
NOTICE
• Do not add DEF more than line F of sight gauge (3). DEF may leak through the breather. When the
ambient temperature is low and DEF may freeze, do not add it more than line (8) of sight gauge (3).
Be careful of the DEF line to be added when performing operations on a slope or traveling on a
rough ground. When the remaining DEF level is low, a warning may be displayed or the engine pow-
er is limited if DEF pump sucks air or if DEF level suddenly drops.
• If DEF is stored in unspecified container, foreign material may mix in it and toxic gas or corrosive
substance may be produced by chemical reactions. When adding DEF, do not transfer it to another
container.
• Do not use a funnel when to add DEF. The strainer may be broken.
• When using a portable DEF refill container, use up DEF each time. If any of DEF is left, seal it, and
remove foreign material, if there is any.
• Do not wash the supply nozzle in city water. Minerals may clog the devices.
• Do not dilute DEF with water.
• If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution
lamp lights up and the audible alert sounds to warn the abnormality. In this case, ask your Komatsu
distributor for draining of the wrong fluid and for inspection. DEF injector and/or DEF pump may
need to be replaced.
3-141
2. Check the DEF level gauge on the machine monitor.

When adding, perform actions written in “DEF LEVEL
CAUTION LAMP (3-23)”.
3. After checking, turn the starting switch back to OFF posi-

tion (A).
4. Check that the engine is stopped.
5. If DEF is insufficient, add DEF.

1) Prepare BIB container (a) (10 ℓ).
2) Put BIB container (a) onto the rear of the track first.
3) Climb on the top of the track from the front of the ma-
chine.
4) Move BIB container to top of the DEF tank filler port
cover (1)
5) Open DEF tank filler port cover (1).

For the opening and closing method of the cover, see
“METHOD FOR OPENING AND CLOSING DEF
TANK FILLER CAP COVER (3-200)”.
6) Clean blue DEF tank filler cap (2) and surrounding
area.
The caps of DEF tanks are blue, as required by emis-
sion regulations.
7) Open blue DEF tank filler cap (2).
For the filler cap opening and closing procedure, see
“METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT CAP (3-201)”
3-142
8) Connect DEF supply hose (b) to BIB container (a).

(c) Connecting side to the BIB container
(d) Inserting side to the DEF filler port
9) Incline BIB container (a) so that valve (e) of DEF sup-

ply hose (b) comes downward.
10) Insert DEF supply hose (b) into filler port (2).
11) Open valve (e) of DEF supply hose (b).
12) By watching sight gauge (3), add DEF through filler

port (2) until float (4) reaches line F (5).
Refill capacity of DEF tank: 23.5 ℓ
Line (6) in the sight gauge indicates approximately 5 ℓ
below line F, and line (7) indicates approximately 10 ℓ.
Line (8) is the max adding line when DEF may freeze
in cold weather.
13) After adding, close valve (e) of DEF supply hose (b).
14) Remove DEF supply hose (b) from DEF tank (f).
15) Align claw (9) of the cap with groove (10) of the filler
port and close the cap securely by turning it clockwise
by 90 °.
3-143
REMARK
• It is recommended to use a nozzle having a diameter and a length specified by ISO 22241-4 and an auto
stop function to add DEF. When the specified nozzle is used, the magnet installed inside the filler port of the
tank cancels the wrong fluid addition prevention device, and you can add DEF. This mechanism prevents
addition of DEF into the fuel tank, addition of fuel into DEF tank, and spill of DEF from the filler port.
• When using a nozzle which is not conformed to ISO 22241-4, hold it in your hand and add DEF carefully
while checking the sight gauge.
• Add only DEF in clearly marked DEF tanks that have the blue cap.
METHOD FOR CHECKING LAMPS OPERATION

2. Set the headlamp switch to night mode (a) and daytime

mode (b), and check that the head lamp lights up in both
mode.
3. Turn the rear lamp switch to ON position (d), and check

that the rear lamp lights up.
If the lamps do not light up, a broken bulb or disconnected
wire are the possible causes. Ask your Komatsu distributor
for repairs.
4. After finishing the check, turn the head lamp to OFF posi-
tion (c) and turn the rear lamp to OFF position (e).
5. Turn the starting switch to OFF position (A).
3-144
METHOD FOR CHECKING MACHINE MONITOR

NOTICE
Do not perform the check before starting only on the monitor. Always perform other checks before start-
ing.
1. Turn starting switch (1) to ON position (B).
2. Check that KOMATSU mark is displayed first and then the
camera screen and the basic monitor screen is displayed
in order, and the buzzer sounds for approximately 2 sec-
onds.
On the machines with no camera (optional) setting, KO-
MATSU mark is displayed first and then the basic monitor
screen is displayed.
If they do not light up, the machine monitor may be defective or open circuit is in the machine monitor. Ask your
Komatsu distributor for the inspection.
METHOD FOR REMOVING DEPOSIT IN ENGINE COMPARTMENT

Check that there is no deposit inside the engine compartment, particularly around the turbocharger, exhaust
manifold, and aftertreatment devices.
If there is any deposit, remove it.
METHOD FOR CHECKING HORN OPERATION

2. Check that the horn sounds when the horn switch is press-
ed.
If the horn does not sound at all or the volume is extremely
weak, a defect or broken wire is suspected, ask your Ko-
matsu distributor for repair.
3-145
3. Return the starting switch to OFF position (A).
METHOD FOR CHECKING BACKUP ALARM OPERATION STATUS

2. Set the parking brake lever (1) to LOCK position (L).
3. Set the joystick (steering, directional and gear shift lever)

in REVERSE position (R).
The alarm must sound immediately at this time.
The alarm keeps sounding until the joystick (steering, di-
rectional and gear shift lever) is set to NEUTRAL position
(N) or FORWARD position (F).
4. After checking the alarm operation, return the joystick
(steering, directional and gear shift lever) to NEUTRAL po-
sition (N) immediately.
5. Return the starting switch to OFF position (A).
METHOD FOR ADJUSTING

METHOD FOR ADJUSTING OPERATOR'S SEAT
k WARNING
• When adjusting the position of the operator's seat, always set the work equipment lock lever and
parking brake lever to LOCK positions to prevent any accidental contact with the control levers.
• When adjusting the operator's seat, stop the machine at a safe place.
NOTICE
If you adjust the operator's seat while parts, tools, empty cans, etc. are left around, the peripheral parts
and operator's seat may be damaged.
Before adjusting the operator's seat, check that there is no part, etc. around it.
• Always adjust the operator's seat before starting each operation or when the operators change shift.
• When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal
can be fully depressed.
3-146
MECHANICAL SUSPENSION SEAT

METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION
1. Pull up the fore-aft adjustment lever, set the seat to the de-
sired position.
Fore-and-aft adjustment: 160 mm (16 stages)
2. After adjusting, release the lever.
METHOD FOR RECLINING SEAT

The reclining of the seat becomes large when the seat is moved forward, and it becomes smaller as the seat is
moved backward. When moving the seat backward, return the reclined seat back to the original position.
1. Pull up the reclining adjustment lever and set the seat
back to a position which is comfortable for operation.
Foremost reclining: Approx. 66 ° (Approx. 1.9 ° x 35 steps)
Rearmost reclining: Approx. 72 ° (Approx. 1.9 ° x 38 steps)
Sit with your back against the backrest when adjusting. If
your back is not touching the backrest, it may suddenly
move forward.
METHOD FOR TILTING SEAT

Pull up the tilt adjustment lever and adjust the front angle of the seat.
• To raise the front of the seat, apply your weight to the rear
of the seat, while pulling up lever.
• To lower the front of the seat, apply your weight to the front
Tilt adjustment: Up 5 °, down 5 ° (3 levels)
3-147
METHOD FOR ADJUSTING WEIGHT AND HEIGHT OF SEAT

Pull out the crank of knob (1) under the seat and turn it so that
weight indicator (2) reads the green range. You can adjust the
height by turning knob (1) in the green range.
X: When crank is stored
Y: When crank is pulled out (for adjusting weight)
1. Adjust the weight according to the following procedure.

1) While the seat is moved backward, turn knob (1) to adjust.
Weight adjustment range: 60 to 150 kg
2) After adjusting the weight, return the crank of knob (1).
2. Adjust the height by turning knob (1) in the green range.
The seat height is increased by turning the knob clockwise (R), seeing from the seated position, and de-
creased by turning the knob counterclockwise (L).
Vertical adjustment range: Steplessly 75 mm
3. After adjusting the weight and height, readjust the seat to the best position in the forward and backward
directions.
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METHOD FOR ADJUSTING LUMBAR SUPPORT

Turn the adjustment knob to the right or left, and give proper
tension to the waist part.
The back cushion tension is increased by turning the adjust-
ment knob to the right.
The tension of the back cushion can be adjusted to 5 steps. If
the adjustment knob is turned to right further after the 5th step,
the tension returns to the 1st step.
METHOD FOR ADJUSTING SEAT DIRECTION

You can change the direction of the seat to 12.5 ° on the right by pulling up the direction adjustment lever to
FREE position (F) and unlock it.
When using the ripper, the operator can work easily by directing the seat to the right.
1. Pull up the direction adjustment lever to FREE position (F)
and unlock it.
The seat direction can be changed to 12.5 °.
2. After changing the seat direction, return the lever to LOCK
position (L) securely.
METHOD FOR HEATING SEAT

Turn the seat heater switch ON.
(a): OFF position
(b): ON position
The backrest and seat surface are heated.
When the seat heater switch is turned ON, the heater in the seat operates. When the seat surface temperature
exceeds approximately 20 °C, the heater is turned OFF automatically. When the temperature decreases below
approximately 10 °C, the heater is turned ON automatically.
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REMARK
When the seat surface temperature is above approximately 20 °C, the heater does not operated even if switch
(8) is turned ON.
AIR SUSPENSION SEAT

(if equipped)
METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION

1. Pull up the fore-aft adjustment lever, set the seat to the de-
sired position.
Fore-and-aft adjustment: 160 mm (16 stages)
METHOD FOR RECLINING SEAT

The reclining of the seat becomes large when the seat is moved forward, and it becomes smaller as the seat is
moved backward. When moving the seat backward, return the reclined seat back to the original position.
1. Pull up the reclining adjustment lever and set the seat
back to a position which is comfortable for operation.
Foremost reclining: Approx. 66 ° (Approx. 1.9 ° x 35 steps)
Rearmost reclining: Approx. 72 ° (Approx. 1.9 ° x 38 steps)
Sit with your back against the backrest when adjusting. If
your back is not touching the backrest, it may suddenly
move forward.
METHOD FOR TILTING SEAT

Pull up the tilt adjustment lever and adjust the front angle of the seat.
• To raise the front of the seat, apply your weight to the rear
• To lower the front of the seat, apply your weight to the front
Tilt adjustment: Up 5 °, down 5 ° (3 levels)
METHOD FOR ADJUSTING WEIGHT AND HEIGHT OF SEAT

When adjusting the allowable weight and height of the seat, turn the starting switch to ON position since the air
compressor built in the seat is used for the adjustment.
NOTICE
Avoid using lever (3) continuously for 1 minute or longer since such practice can damage the air com-
pressor.
The seat height is adjusted pneumatically and in stepless.
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The seat height can be adjusted by fully pressing down or pull-

ing up lever (2).
When it is adjusted to the desired position, you can release the
lever.
When raising, pull up the lever until it clicks.
If the lever is pulled up and held, the seat stops at the maxi-
mum height.
If the seat is raised to the maximum height, the suspension
lowers a little automatically to secure some stroke.
If you raise your hip or change the load on the seat during ad-
justment, the air in the suspension may be released.
Vertical adjustment range: 75 mm
Weight adjustment range: 60 to 150 kg
The suspension must be adjusted according to the operator's weight to protect the operator. For this purpose,
when adjusting, stop the machine and operate the lever while you are sitting in the correct position.
Pull up lever (2) a little. The suspension is adjusted to your weight automatically. (The air pressure in the sus-
pension increases or decreases according to your weight).
METHOD FOR ADJUSTING LUMBAR SUPPORT

Turn the adjustment knob to the right or left, and give proper
tension to the waist part.
The back cushion tension is increased by turning the adjust-
ment knob to the right.
The tension of the back cushion can be adjusted to 5 steps. If
the adjustment knob is turned to right further after the 5th step,
the tension returns to the 1st step.
METHOD FOR ADJUSTING SEAT DIRECTION

You can change the direction of the seat to 12.5 ° on the right by pulling up the direction adjustment lever to
FREE position (F) and unlock it.
When using the ripper, the operator can work easily by directing the seat to the right.
1. Pull up the direction adjustment lever to FREE position (F)
and unlock it.
The seat direction can be changed to 12.5 °.
2. After changing the seat direction, return the lever to LOCK
position (L) securely.
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METHOD FOR HEATING SEAT

Turn the seat heater switch ON.
(a): OFF position
(b): ON position
The backrest and seat surface are heated.
When the seat heater switch is turned ON, the heater in the seat operates. When the seat surface temperature
exceeds approximately 20 °C, the heater is turned OFF automatically. When the temperature decreases below
approximately 10 °C, the heater is turned ON automatically.
REMARK
When the seat surface temperature is above approximately 20 °C, the heater does not operated even if switch
(8) is turned ON.
METHOD FOR ADJUSTING MIRRORS

k WARNING
Be sure to adjust the mirrors before starting work.
If they are not adjusted properly, you cannot secure the visibility and may be injured or may lead to a
Loosen nut (1) installed to the mirror.

Adjust position of the mirrors so that they can be seen most
easily from the operator's seat.
In particular, be sure to adjust the mirror so that people at the
rear left or right of the machine can be seen clearly.
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METHOD FOR ADJUSTING JOYSTICK (STEERING, DIRECTIONAL AND GEAR

SHIFT LEVER) (PCCS LEVER)
k WARNING
After moving case (2) in order to adjust the position of the joystick (steering, directional and gear shift
lever) (PCCS lever), secure lock lever (1) into the notched hole, making sure it is in LOCK position.
If the locking condition is unstable, when the joystick (steering, directional and gear shift lever) is oper-
ated, the machine may move unexpectedly and can cause personal injury or death.
You can move and adjust the joystick (steering, directional and gear shift lever) to 9 steps in the forward/back-
ward range of 90 mm. Adjust to the most suitable position to match the adjustment of the operator's seat.
1. Pull up lock lever (1) at the rear of case (2) on the left side
of the operator's seat, and set it to FREE position (F).
2. While pulling up lock lever (1) with one hand, hold the front
part of case (2) with the other hand, and move in the for-
ward and backward directions with both hands.
The joystick (steering, directional and gear shift lever)
moves together with the case.
3. While moving, set the case to a desirable clicking position,

and release lock lever (1).
Lock lever (1) returns automatically to LOCK position (L).
REMARK
PCCS: Abbreviation for Palm Command Control System
METHOD FOR ADJUSTING ARMREST

The R.H. and L.H. armrests of the operator's seat can be adjusted in height as shown below. After adjusting the
operator's seat, adjust them to proper height.
METHOD FOR ADJUSTING RIGHT ARMREST

R.H. armrest (1) can be adjusted to 20 mm and 40 mm above and 20 mm below the standard height, to 4 steps
in total.
1. Set lock lever (2) to FREE position (F). (2 places)
2. Move armrest (1) forward.
3. Set to a hole at a desirable height.
4. While holding armrest (1) to the desirable height, set lock
lever (2) to LOCK position. (2 places)
Armrest (1) is fixed.
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METHOD FOR ADJUSTING LEFT ARMREST

The L.H. armrest of the operator's seat can be adjusted upward steplessly from the contact face of the armrest
and case to 36 mm.
The joystick (steering, directional and gear shift lever) does not move.
1. Open the armrest.
2. Turn knob (3) counterclockwise (to the left).
Only the armrest moves up.
After setting the armrest to a desirable height, close it.
METHOD FOR FASTENING AND UNFASTENING SEAT BELT

k WARNING
• Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If
it is worn or damaged, replace it.
• Even if no problem can be seen in the belt, replace the seat belt every 3 years from starting usage
or 5 years after manufacture whichever comes sooner. The date of manufacture of the belt is shown
on the back of the belt.
• Be sure to use the seat belt during operation.
• Do not twist the seat belt when fastening.
REMARK
The date indicated on the seat belt is the manufactured date. It is the start of the 5-year period. It is not the start
of the 3-year period of actual usage.
CHECK SEATBELT
Check for looseness of the mounting bolts of the metal fittings which are installing the seatbelt to the machine.
If they are loosened, retighten them.
Tightening torque: 25 ± 5 Nm {2.5 ± 0.5 kgm}
NOTICE
If the seatbelt has flaw, fuzz, breakage, or deformation after long-time use, replace it.
METHOD FOR FASTENING SEAT BELT

Sit on the seat, depress the brake pedal fully, and adjust the seat so that your back is pressed against the back-
rest.
1. Hold grip (2) and pull out the belt from retractable device
(1).
2. Check that the belt is not twisted, and then inset tongue (3)
into buckle (4) securely.
Fit the belt along your body without twisting.
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3. Pull the belt lightly to check that it is properly locked.

If the tongue is not inserted in the buckle, the seat belt
caution lamp is displayed at the top left of the machine
monitor.
METHOD FOR UNFASTENING SEAT BELT

Press button (5) in buckle (4) and remove tongue (3) from
buckle (4).
The belt is automatically wound in, hold grip (2) and return the
belt slowly to retractable device (1).
METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE

k WARNING
• When starting the engine, check and make sure park-
ing brake lever (1) and work equipment lock lever (4)
are secured in LOCK position.
If the work equipment control levers are not locked
and they are touched by accident when starting the
engine, the work equipment may move unexpectedly,
and this may lead to a serious injury or death.
• When standing up from the operator's seat, always set
parking brake lever (1) and work equipment lock lever
(4) to LOCK position, regardless of whether the engine
is running or stopped.
1. Check that battery disconnect switch (S) is in ON position

(I).
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2. Check that parking brake lever (1) is in LOCK position (L).

If parking brake lever (1) is not in LOCK position (L), the
engine cannot be started.
3. Check that joystick (steering, directional and gear shift lev-

er) (2) is in NEUTRAL position (N).
The engine cannot be started if joystick (steering, direc-
tional and gear shift lever) (2) is not in neutral position (N).
If joystick (steering, directional and gear shift lever) (2) is in

F or R, the letter “P” on gear speed display will flash.
4. Lower the blade to the ground.

For blade operation, see “BLADE CONTROL LEVER
(3-87)”.
5. Check that blade control lever (3) is in HOLD position (b).
6. Lower the ripper to the ground.
For ripper operation, see “RIPPER CONTROL LEVER
(3-95)”.
7. Check that work equipment lock lever (4) is in LOCK posi-

tion (L).
If work equipment lock lever (4) is not in LOCK position
(L), the engine cannot be started.
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8. Turn fuel control dial to Low idle (MIN) position.

When the dial is in High idle (MAX) position, be sure to set
it to Low idle (MIN) position.
REMARK
Even if the engine is started with the fuel control dial in a
position other than Low idle (MIN) position, the engine
speed is set to low idle.
You can change the engine speed by turning the fuel con-
trol dial to Low idle (MIN) position and then turning it to-
ward high idle (MAX) position.
9. Insert the key into starting switch and turn it to ON position
(B).
10. On the input display screen displayed on the machine

monitor, input the password and press switch F6.
If a password is set, the input display screen will be indi-
cated on the machine monitor.
REMARK
Contact your Komatsu distributor for details of the method
of setting, changing, or canceling the password.
11. Perform the following inspection on the machine monitor.
1) Check that the buzzer sounds for approximately 2

seconds and the camera image is displayed.
(When camera is set)
2) Check that the following caution lamp and gauge

lights up for approximately 2 seconds.
• Power train oil temperature gauge (5)
• Engine coolant temperature gauge (6)
• Charge level caution lamp (7)
• Water separator caution lamp (8)
• Engine oil pressure caution lamp (9)
• Hydraulic oil temperature gauge (10)
• Fuel gauge (11)
• Gear speed display (12)
3-157
If any caution lamp does not light up or the buzzer does not sound, there is probably a failure in the
machine monitor, so ask your Komatsu distributor for repair.
3) Check that the screen will change to the preset (speed
range to start) display screen in approximately 2 sec-
onds, then it will change to the standard screen.
• Power train oil temperature gauge (5)
• Engine coolant temperature gauge (6)
• Hydraulic oil temperature gauge (10)
• Fuel gauge (11)
• Gear speed display (12)
• Multi-gauge (13)
• DEF level gauge (14)
• DEF level caution lamp (15)
4) If the multi-gauge goes out and caution lamp (16)

stays lit, immediately check the lit item.
For details of contents and check methods for caution
lamp, see “WARNING DISPLAY (3-13)”.
12. When the maintenance time caution lamp (17) is lit, press
switch F6 to check the item, and perform the maintenance
immediately.
If the maintenance due time has passed for certain items,
maintenance time caution lamp (17) is lit for 30 seconds.
For details of the method of checking the maintenance in-
terval, see “MAINTENANCE SCREEN SETTING (3-67)”.
3-158
METHOD FOR STARTING ENGINE

METHOD FOR STARTING ENGINE IN NORMAL WEATHER
k WARNING
• Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may
cause a fire or serious personal injury or death.
• Check that there are no people or obstacles in the surrounding area, then sound the horn and start
the engine.
• Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure
good ventilation.
• Do not approach the exhaust pipe outlet of the engine while the engine is running or just after it is
stopped.
Also, keep combustible materials away from the exhaust pipe outlet.
NOTICE
• Do not turn the starting motor continuously for more
than 60 seconds in any case. If the engine does not
start, wait for approximately 2 minutes, then repeat the
procedure from step 2.
• Before starting the engine, check that fuel control dial
(1) is at Low idle (MIN) position.
• The machine is equipped with a function to automati-
cally warm up engine coolant temperature more quick-
ly and another function to protect the turbocharger.
When fuel control dial (1) is operated just after the en-
gine is started in cold weather, the engine speed may
not change for several seconds.
• Even if the engine is started with fuel control dial (1) in
a position other than Low idle (MIN) position, the en-
gine speed is set to low idle.
You can change the engine speed by turning fuel con-
trol dial (1) to Low idle (MIN) position and then turning
it toward High idle (MAX) position.
1. Turn fuel control dial (1) to Low idle (MIN) position.
3-159
2. Turn starting switch key (2) to START position (C).

The engine starts.
3. When the engine starts, release the starting switch key (2).
The key will return automatically to ON position (B).
REMARK
• White smoke may be discharged for a short time immediately after the engine is started or during the after-
treatment devices regeneration in the cold season, but this is not a failure.
• The smell of the exhaust gas is different from that of the conventional diesel engine because of the exhaust
gas filtering function.
METHOD FOR STARTING ENGINE IN COLD WEATHER

k WARNING
• Do not attempt to start the engine by short-circuiting the engine starting circuit. Doing so may
cause a fire or serious personal injury or death.
• Check that there are no people or obstacles in the surrounding area, then sound the horn and start
the engine.
• Never use starting aid fluids as they may cause explosions.
• Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure
good ventilation.
• Do not approach the exhaust pipe outlet of the engine while the engine is running or just after it is
stopped.
Also, keep combustible materials away from the exhaust pipe outlet.
3-160
NOTICE
• In all cases, do not turn the starting motor continuous-
ly for more than 60 seconds. If the engine does not
start, wait for approximately 2 minutes, then repeat the
procedure from step 2.
• Before starting the engine, check that fuel control dial
(1) is at Low idle (MIN) position.
• The machine is equipped with a function to automati-
cally warm up engine coolant temperature more quick-
ly and another function to protect the turbocharger.
When fuel control dial (1) is operated just after the en-
gine is started in cold weather, the engine speed may
not change for several seconds.
• Even if the engine is started with the fuel control dial
(1) in a position other than Low idle (MIN) position, the
engine speed is set to low idle.
You can change the engine speed by turning the fuel
control dial (1) to Low idle (MIN) position and then
turning it toward High idle (MAX) position.
2. Turn the key in starting switch (2) to ON position (B).
3-161
3. Check if preheating pilot lamp (3) on the machine monitor

is lit.
4. Leave this condition until preheating pilot lamp (3) goes
out.
5. After preheating pilot lamp (3) goes out, turn the key of
starting switch (2) to START position (C), and start the en-
gine.
The lighting time of preheating pilot lamp (3) varies with
the ambient temperature as shown in the table.
Ambient temperature
Lighting time (sec.)
( °C)
-3 to -10 5 to 15
-10 to -20 15 to 32
-20 to -30 32 to 45
6. When the engine starts, release the starting switch key (2).
The key will return automatically to ON position (B).
REMARK
Just after starting the engine, run it at low idle. During this
period, release the decelerator pedal and perform no oper-
ation of the work equipment.
7. After the engine speed is stabilized, perform the warm-up
operation.
3-162
REMARK
• Regardless of the ambient temperature, if the starting switch (2) is turned counterclockwise from OFF posi-
tion, engine preheating pilot lamp (3) lights up and preheating starts. (Pre-heating continues while the start-
ing switch (2) is held at the left.)
For the details of the preheat time, see the table in step 5.
• While preheating is being performed, engine preheating pilot lamp (3) lights up to show that preheating is
being performed.
• If the engine does not start with the above operation, wait for approximately 2 minutes, and repeat steps 3.
and 4.
• Urea SCR system has the function of heating and keeping itself warm to prevent freezing of DEF.
If DEF is frozen, the DEF system is heated to thaw the DEF automatically after the engine starts. The devi-
ces do not operate until DEF is thawed and supplied, but this does not indicate any abnormality.
When the ambient temperature decreases to a level where the DEF may freeze while the machine is in op-
eration, the DEF system is warmed automatically to prevent freezing. When the ambient temperature de-
creases to a level where freezing of DEF is not preventable, the devices stop automatically, but this does
not indicate any abnormality.
• If DEF freezes, thawing operation is performed automatically. Never heat DEF.
Harmful ammonia gas may be generated.
Turbo protect function
The turbo protect function protects the turbocharger by keeping the engine speed at approximately 1000 rpm or
less immediately after the engine is started.
When the turbo protect function and automatic warm-up function operate at the same time, the turbo protect
function is given priority.
• When the turbo protect function is actuated, the engine speed is held at 1000 rpm, even if the fuel control
dial is turned to a position of 1000 rpm or higher.
• When the turbo protect function is canceled, the engine speed is set to the speed for the position of the fuel
control dial.
• The relationship between the actuating time of the turbo protect function and the temperature of the engine
coolant is as shown in the table.
Coolant temperature
Turbo protect time (sec.)
( °C)
Min. 10 0
10 to -30 Variable between 0 and 20
Max. -30 20
Automatic warm-up function

The automatic warm-up function increases the idle speed to 1200 rpm to increase the engine coolant tempera-
ture quickly during operation at low temperature.
When the turbo protect function and automatic warm-up function operate at the same time, the turbo protect
function is given priority.
• When the automatic warm-up function is actuated, the engine speed is held at 1200 rpm, even if the fuel
control dial is turned to a position of 1200 rpm or lower.
However, if the fuel control dial is held at High idle (MAX) position for more than 3 seconds, the auto warm-
up function is canceled and then the engine speed can be lowered below 1200 rpm.
• The automatic warm-up function continues operation until the engine coolant temperature reaches 30 °C or
up to 10 minutes.
• If the decelerator pedal is depressed while the automatic warm-up function is in operation, the automatic
warm-up function is canceled and the engine speed decreases below 1200 rpm.
3-163
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE

k WARNING
• If there has been any emergency stop, abnormal actuation or trouble, turn the starting switch key to
OFF position.
• If the work equipment is operated without sufficient warming-up operation of the machine, response
of the work equipment to movement of the control lever will be slow, and the work equipment may
not respond as the operator desires, so always perform the warming-up operation. Particularly in a
cold weather, be sure the warm-up operation is completed.
• If the machine is operated without sufficient warming-up operation, sensors may break because of
frozen DEF tank.
METHOD FOR CHECKING STARTING CONDITION AND UNUSUAL NOISE OF

ENGINE
• When starting the engine, check that the engine causes no abnormal noise and that it starts up easily and
smoothly.
• Check that there is no abnormal noise when the engine is idling or when the engine speed rises slightly.
When there is an abnormal noise at the engine startup and if that condition continues, the engine may be dam-
aged. In that case, ask your Komatsu distributor to check the engine as soon as possible.
METHOD FOR CHECKING LOW-SPEED RUN AND ACCELERATION OF ENGINE

k CAUTION
• Perform these checks in a safe place, watching out for danger in the surroundings.
• When the engine performs very badly at low idle and in the acceleration and if that condition contin-
ues, it may damage the engine or confuse the operator's sense of driving or lower the braking effi-
ciency, and as a result lead to an unexpected accident. In that case, ask your Komatsu distributor to
check the engine as soon as possible.
• When stopping the machine during the normal traveling operation, check that the engine does not hunt or
stop suddenly.
• Check that the engine speed rises smoothly when the fuel control dial is turned to High idle (MAX) position.
REMARK
• The smell of the exhaust gas is different from that of the conventional diesel engine because of the exhaust
gas filtering function.
• White smoke may be discharged for a short time immediately after the engine is started or during the KDPF
regeneration in the cold season, but this is not a failure.
METHOD FOR RUNNING-IN THE NEW MACHINE

NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory.
However, operating the machine under full load before breaking the machine in can adversely affect the
performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the descriptions in this manual, then run in the machine while paying atten-
tion to the following points.
• Run the engine at idle for 15 seconds immediately after starting it up.
Do not operate the control levers or fuel control dial during this time.
• Perform warm-up operation for 5 minutes after the engine is started.
• Avoid operation with heavy loads or at high speeds.
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• Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden
stops, and sudden changes in direction of the machine.
METHOD FOR ENGINE WARM-UP OPERATION

NOTICE
• Do not perform operations or operate the levers sharp-
ly while the hydraulic oil is at low temperature. Always
perform the warm-up operation until the hydraulic oil
temperature caution lamp shows the green display.
Performing the warm-up operation properly will extend
the service life of the machine.
Do not accelerate the engine abruptly until it is
warmed up.
• Do not run the engine at low idle or high idle under no
load for more than 20 minutes. This will have an ad-
verse effect on the environment and also on the inter-
nal structure of the turbocharger and engine. If it is
necessary to run the engine at idling, apply a load
from time to time or run at a medium speed.
• If the engine oil pressure caution lamp on machine
monitor (2) lights up or the alarm buzzer sounds inter-
mittently, stop the engine and perform inspection.
1. Turn fuel control dial (1) to a position midway between Low

idle (MIN) and High idle (MAX).
The engine runs at a medium speed.
2. Run under no load (perform warm-up operation) for ap-
proximately 5 minutes.
3. After the warm-up operation, check that each gauge and
caution lamp indicate the normal values.
If any problem is found, perform maintenance or repair.
4. Operate under light load until the engine coolant tempera-

ture gauge on machine monitor (2) indicates green range
(A) to (C).
• (A) to (B): Red range
• (A) to (C): Green range
• (C) to (D): White range
5. Check for abnormal exhaust gas color, noise, or vibration.
If any abnormality is found, contact your Komatsu distribu-
tor.
REMARK
The cooling fan speed varies according to the following conditions, but it is not abnormal.
The cooling fan speed increases when the hydraulic oil temperature , engine coolant temperature, or power
train oil temperature is high.
If the air-conditioner is running, the cooling fan rotates at a higher speed even if these temperature is low.
3-165
METHOD FOR ENGINE WARM-UP OPERATION IN COLD SEASON

This machine is warmed up automatically by the automatic
warm-up operation system.
When the engine coolant temperature is 30 °C or less after the
engine is started, the warm-up operation starts automatically.
The automatic warm-up operation stops when the engine cool-
ant temperature increases the specified temperature (30 °C) or
after warm-up operation of 10 minutes even if the coolant tem-
perature does not increase to 30 °C.
After the automatic warm-up operation, if the engine coolant
temperature or hydraulic oil temperature is low, perform addi-
tional warm-up operation according to the following procedure.
1. Turn fuel control dial (1) to a position midway between Low
idle (MIN) and High idle (MAX).
Engine runs at medium speed.
2. Run it under no load (warm-up operation) for approximate-
ly 10 minutes.
3. Raise the blade to the highest position by operating blade

control lever (2).
For blade operation, see “BLADE CONTROL LEVER
(3-87)”.
4. Repeat the following relief operations for 5 minutes with
the blade raised to the highest position.
1) Operate slowly LEFT TILT relief.
2) Operate slowly RIGHT TILT relief.
5. Next, repeat the following relief operations for 5 minutes.
1) Operate blade control lever (2) to RAISE position (a)
(at lever stroke end) and hold it in that position, then perform RIGHT and LEFT TILT relief operations
intermittently.
2) Lower the blade to the ground.
3) Operate blade control lever (2) to FLOAT position (d) (at lever stroke end) and hold it in that position,
then perform RIGHT and LEFT TILT relief operations intermittently.
4) Raise the blade to the highest position.
6. After completing relief operations, lower the blade to the ground.
7. Operate blade control lever (2) to FLOAT position (d) (at lever stroke end) and hold it with your hand for 1
minute.
8. Even when releasing blade control lever (2), check that blade control lever (2) is at FLOAT position (d).
9. After 3 minutes, return blade control lever (2) to HOLD position (b).
10. After the warm-up operation, check that each gauge and caution lamp indicate the normal values.
If any problem is found, perform maintenance or repair.
3-166
11. Operate it under light load until the engine coolant temper-
ature gauge on machine monitor (3) indicates green range
(A) to (C).
REMARK
If the power train oil temperature is not sufficiently high, it
takes longer to reach the maximum speed.
12. Check for abnormal exhaust gas color, noise, or vibration.
If any abnormality is found, contact your Komatsu distributor.
METHOD FOR STOPPING ENGINE

k WARNING
Keep away from the exhaust pipe immediately after stopping the engine.
NOTICE
• If the engine is abruptly stopped before it has cooled
down, service life of the engine parts may be reduced.
Do not stop the engine abruptly except in an emergen-
cy.
If the engine overheats, do not stop it suddenly. Run it
at low speed to allow it to cool down gradually, then
stop it.
• If the engine is stopped during Aftertreatment Devices
Regeneration, the components may be damaged. Stop
the regeneration first according to “PROCEDURE FOR
AFTERTREATMENT DEVICES REGENERATION DISA-
BLE SETTING (3-110)”, then stop the engine as fol-
lows.
• When the engine is stopped during or just after the af-
tertreatment devices regeneration is finished, the parts
temperatures around aftertreatment devices may be-
come high. Take care.
1. Lower the work equipment to the ground.
3. Run the engine at low idle for approximately 5 minutes to
cool down gradually.
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4. Turn the key in starting switch (2) to OFF position (A).

The engine will stop.
5. Remove the key from starting switch (2).

REMARK
• When engine starting switch (2) is turned to OFF posi-
tion, the engine stops, but the machine's main power
supply is not turned off immediately.
During this period, the power is supplied to the con-
troller to save the operating condition and then finish
the system. The time to keep supplying the power de-
pends on the operating condition.
• Also when the hydraulic fan is turned in reverse, the
machine's main power supply is not turned off immedi-
ately, even if the key in engine starting switch (2) is
turned to OFF position.
This is for protection of the hydraulic circuit, and the
power is kept supplied for 7 seconds.
• If the starting switch (2) key is turned to OFF position
(A) while the engine is still hot, guidance (3) may be
displayed on the machine monitor. To cool down the
engine before stopping, run it at low idle the next time
and after, because it may cause damage to the devi-
ces.
• After the engine is stopped, DEF in DEF injector and
pump is automatically purged and returned to the tank
to prevent malfunction of the devices caused by freez-
ing of DEF or deposition of urea.
For this purpose, the devices keep operating up to 7
minutes after starting switch (2) is turned to OFF posi-
tion, and this does not indicate abnormality.
In addition, the system operating lamp lights up while
devices are operating to purge DEF to the tank. Do
not turn the battery disconnect switch to OFF position
while the system operating lamp is lit. After all DEF is
purged, the devices stop automatically.
3-168
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE)

AND STOPPING MACHINE
METHOD FOR MOVING MACHINE
k WARNING
• Before moving the machine off, check that the area
around the machine is safe, then sound the horn be-
fore starting.
• Keep people away from the machine.
• The area behind the machine is a blind spot. Particu-
larly pay attention when traveling in reverse.
• When moving the machine down a slope, always keep
brake pedal (8) depressed, even after releasing park-
ing brake lever (1).
• When moving the machine off on a steep uphill, turn
fuel control dial (5) to High idle (MAX) position and run
the engine at full speed. While keeping brake pedal (8)
and decelerator pedal (6) depressed, operate joystick
(steering, directional and gear shift lever) (7) from the
N (neutral) position to the direction of travel and slow-
ly release brake pedal (8). When increasing the travel
speed, slowly release decelerator pedal (6).
1. Set parking brake lever (1) to FREE position (F).
2. Set work equipment lock lever (2) to FREE position (F).
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3. Set blade control lever (3) to RAISE position (A) and raise
the blade to 40 to 50 cm above the ground.
4. Set ripper control lever (4) to RAISE position (a) and raise
the ripper to the upper limit.
5. Turn fuel control dial (5) to High idle (MAX) position and in-
crease the engine speed.
6. Depress decelerator pedal (6) fully.
7. Set the joystick (steering, directional and gear shift lever)

(7) to FORWARD position (F) or REVERSE position (R).
8. Start the machine by releasing decelerator pedal (6) grad-
ually.
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METHOD FOR STOPPING MACHINE

k WARNING
• Avoid a sudden stop. Stop the machine gradually.
• Do not park the machine on a slope.
If it is unavoidably necessary to park the machine on a
slope, place parking brake lever (1) in LOCK position
and insert blocks underneath the track shoes to pre-
vent the machine from moving. As an additional safety
measure, thrust the work equipment into the ground.
• If the work equipment control lever is touched by acci-
dent, the work equipment may suddenly move, and
this may cause serious personal injury or death. Be-
fore leaving the operator's seat, always secure work
equipment lock lever (2) in LOCK position.
1. Depress brake pedal (3) to apply the brake.

NOTICE
If the brake pedal is depressed when the engine speed
or travel speed is high, the brake disc may make a
slipping sound. When depressing the brake pedal, de-
press decelerator pedal (4) to reduce the engine speed
and machine travel speed.
2. Return joystick (steering, directional and gear shift lever)

(5) to N (Neutral) position.
3. Depress brake pedal (3) further.
The machine stops.
SHIFT GEARS
k WARNING
When the machine is traveling on a flat ground or down a slope, never set the joystick (steering, direc-
tional and gear shift lever) to N (neutral) position. Always keep it in a gear speed when traveling.
When traveling with the joystick (steering, directional and gear shift lever) in N (neutral) position, always
decelerate, and then change the travel direction.
There may also be damage to the transmission or other parts of the power train, and there is danger of
unexpected accidents.
The machine does not have to be stopped to shift gears.
3-171
Shit the gear by moving joystick (steering, directional and gear

shift lever) (1).
METHOD FOR SHIFTING GEARS

Press switch (a) or (b) to shift the gear.
Up switch (a): The gear is shifted up by 1 step each time this
switch is pressed.
Down switch (b): The gear is shifted down by 1 step each time
this switch is pressed.
The transmission has the following gear speeds.
Automatic gear shift mode: 1, 2, 3L, 3 (4 forward, 4 reverse)
Manual gear shift mode: 1, 2, 3 (3 forward, 3 reverse)
For the maximum travel speed in each gear speed, see
“SPECIFICATIONS (5-2)”.
REMARK
When the gear is shifted, the current gear speed is displayed in
the gear speed display section of machine monitor (2).
(Example)
Neutral: “N” is displayed in the gear speed display section.
Forward 2nd: “F2” is displayed in the gear speed display sec-
tion.
Reverse 3rd: “R3” is displayed in the gear speed display sec-
tion.
When the parking brake lever is locked: “P” is displayed in the
gear speed display section.
OUTLINE OF GEAR SHIFT MODE

There are automatic shift mode and manual shift mode in the gear shift mode. Select the mode to match the
use.
Automatic shift mode
Mode for general dozing work. The speed range is shifted down automatically when the load increases, and
shifted up to the set maximum speed range when the load decreases. The torque converter lockup operates
and the optimum speed range is selected automatically, according to the load. This mode is excellent in fuel
economy and production.
Manual shift mode
A mode for dozing and ripping of rough ground. When the auto shift down is ON, if a load is applied, the speed
range automatically shifts down, but when the load is removed, the speed range does not automatically shift up.
When the automatic downshift is OFF, the speed range must be shifted up and down manually. Select the Auto
Shift Down in the customize mode.
3-172
METHOD FOR CHANGING GEAR SHIFT MODE

Press the gear shift mode selector switch when in neutral.
The Auto Shift Mode and Manual Shift Mode are switched to
each other.
DISPLAY OF GEAR SHIFT MODE

The gear shift mode is displayed in the gear shift mode display section of the monitor panel as shown below.
(A) Automatic shift mode
(1) Present speed range
(2) Preset (speed range when moving machine off) and maxi-
mum speed range when traveling
(3) “AUTO” mark displaying automatic mode
(4) Mark displaying automatic mode
(B) Manual shift mode
(5) Present speed range
(6) Preset (speed range when moving machine off)
(7) “MAN” mark displaying manual mode
(8) Mark displaying manual mode
Display color of “MAN” mark (7)
When auto shift down ON is selected: Lights up in blue.
When auto shift down OFF is selected: Lights up in gray (back-
ground color).
METHOD FOR PRESET SETTING WITH SHIFT SWITCH OPERATION IN NEU-

TRAL
The maximum gear speed during travel (automatic shift mode) and the gear speed at start (manual shift mode)
are preset by operating the shift switch in NEUTRAL.
Set the maximum current gear speed.
3-173
Manual shift mode

Set the starting gear speed.
REMARK
When the starting switch is turned ON, the mode is set auto-
matically to automatic mode (set to “F1-R1”).
When the gear shift mode is switched, “F1-R1” is selected as
the default.
METHOD FOR GEARSHIFTING OPERATION USING PRESET MODE FUNCTION

Preset mode selection means the function that sets the maximum gear speed (automatic gear shift mode) or
starting gear (manual gear shift mode) speed beforehand.
When the joystick (steering, directional and gear shift lever) is in neutral position (N), you can change the gear
shift mode by pressing UP switch (a) or DOWN switch (b).
• F1-R1 mode
• F1-R2 mode
• F2-R1 mode
• F2-R2 mode
• F2-R3L mode
• F3L-R3L mode
Manual gear shift mode
• F1-R1 mode
• F1-R2 mode
• F2-R1 mode
• F2-R2 mode
• F2-R3 mode
The selected gear shift mode is displayed on the gear speed display portion of the machine monitor.
Gear shift operation when “F1-R1” mode is set
When the joystick (steering, directional and gear shift lever) is
operated to the front (FORWARD operation), the gear speed
shifts to F1. When it is tilted back (reverse travel operation), the
gear speed is set to R1.
When the joystick (steering, directional and gear shift lever) is
in neutral position (N), if UP switch is pressed once, the mode
is set to “F1-R2” mode. Then, when the joystick (steering, di-
rectional and gear shift lever) is titled forward (forward travel
operation), the gear speed is set to F1. When it is tilted back (reverse travel operation), the gear speed is set to
R2.
When the joystick (steering, directional and gear shift lever) is in N (Neutral) position, if you press the up switch
3 times, “F2-R2” mode is selected. After that, if the joystick (steering, directional and gear shift lever) is operated
forward (FORWARD operation), the gear speed shifts to F2. When it is tilted back (reverse travel operation), the
gear speed is set to R2.
3-174
METHOD FOR CHANGING GEAR SPEED WITH SHIFT SWITCH OPERATION

WHILE TRAVELING
It is possible to operate the shift switch when traveling to change the maximum set gear speed when traveling
(Automatic Shift Mode) or gear speed used when traveling (Manual Shift Mode).
Automatic Shift Mode
Changing the maximum gear speed while the machine is trav-
eling
• During forward travel: The maximum gear speed can be
set to F1 to F3.
• During reverse travel: The maximum gear speed can be
set to R1 to R3.
Up switch (a): Each time this is pressed, gear speed used goes
up one range.
Down switch (b): Each time this is pressed, gear speed used
goes down one range.
REMARK
• F3L and R3L are the gear speeds where the engine is
controlled in 3rd to set intermediate speed between 2nd
and 3rd.
• When the machine starts on a uphill ground in 3L, the gear
speed is set to 2nd for the safety, depending on the condi-
tion of the machine. For example, when the machine starts
by shifting from N to F3L on a uphill ground, the gear
speed may be shifted from N to F2, and then to F3L ac-
cording to the load.
• If the maximum gear speed has been changed while trav-
eling, return the joystick (steering, directional and gear
shift lever) to NEUTRAL position. The setting is returned to
the maximum gear speed set in the preset mode before
starting to travel (when the transmission was at NEU-
TRAL).
• The preset cannot be changed during travel.
NOTICE
• Do not move close to the edge of a cliff unnecessarily.
When dropping soil at the edge of a cliff to build an
embankment or landfill, always leave one load and use
the next load to push the previous load over.
• When reaching the top of a hill, or at the instant when
the load is dumped from a cliff, the load will suddenly
drop and there is danger that the machine will sudden-
ly increase speed, so depress the decelerator pedal to
reduce the speed when dumping the load.
• In Automatic Shift Mode, when a load is applied, the
transmission automatically shifts down; when the load
is removed, it automatically shifts up to the maximum
set gear speed.
3-175
Manual Shift Mode

Changing maximum gear speed used when traveling
• When traveling forward: Possible to change gear speed
used from F1 through F3
• When traveling in reverse: Possible to change gear speed
used from R1 to R3
Up switch (a): Each time this is pressed, gear speed used goes
up one range.
Down switch (b): Each time this is pressed, gear speed used
goes down one range.
REMARK
The preset cannot be changed during travel.
NOTICE
• Do not move close to the edge of a cliff unnecessarily.
When dropping soil at the edge of a cliff to build an
embankment or landfill, always leave one load and use
the next load to push the previous load over.
• When reaching the top of a hill, or at the instant when
the load is dumped from a cliff, the load will suddenly
drop and there is danger that the machine will sudden-
ly increase speed, so depress the decelerator pedal to
reduce the speed when dumping the load.
• When the automatic shiftdown is ON, the gear speed is
shifted down automatically when the load increases,
but is not shifted up automatically when the load de-
creases.
When the automatic shiftdown is OFF, the gear speed
must be shifted up and down manually.
You can select the auto shift down in the customize
mode.
METHOD FOR SWITCHING BETWEEN FORWARD AND REVERSE

k WARNING
When switching the travel direction between FORWARD
and REVERSE, check the safety in new direction in which
the machine moves.
k CAUTION
You can switch the forward/reverse travel direction without
stopping the machine. However, for the safety, operator
comfort, and service life of the power train, it is recom-
mended not to switch with the engine speed increased but
depress the decelerator pedal, decrease the engine speed,
and then switch.
3-176
1. Depress decelerator pedal (1) to reduce the engine speed.
2. Set joystick (steering, directional and gear shift lever) (2) to

a desired position.
3. Gradually release decelerator pedal (1) and raise the en-

gine speed.
REMARK
• When the joystick (steering, directional and gear shift
lever) (2) is placed in REVERSE position (R), the
backup alarm will sound.
• When changing the direction of travel when traveling
downhill, depending on the condition of the machine,
the machine may be started in 1st. For example, if you
shift the gear from F2 to R2 while depressing the de-
celerator pedal, the gear speed may change from F2
to R1.
METHOD FOR STEERING MACHINE

k WARNING
• Avoid turning on a slope whenever possible, since sideways slip occurs easily.
Take care particularly on soft ground or clay land.
• Do not make a pivot turn at a high speed.
METHOD FOR NORMAL SWING OPERATION

During travel, tilt joystick (steering, directional and gear shift
lever) (1) in a direction you wish to turn.
The machine turns in a direction in which joystick (steering, di-
rectional and gear shift lever) (1) tilted.
3-177
METHOD FOR TURNING THE MACHINE WHILE TRAVELING FORWARD

When gradually turning to the left, tilt the joystick (steering, di-
rectional and gear shift lever) forward and tilt it to left (L) half-
way.
REMARK
When gradually turning to the right, tilt the joystick (steering, di-
rectional and gear shift lever) forward and tilt it to right halfway.
Operate similarly during reverse travel.
METHOD FOR COUNTER-ROTATION TURN

NOTICE
• Before performing a counter-rotation turn, check the safety around the machine.
• When performing a counter-rotation turn, if the load is not equal on the left and right sides, the ma-
chine may perform a pivot turn, so check the ground conditions and be careful not to hit any obsta-
cles.
When performing counter-rotation turn to the left, set joystick
(steering, directional and gear shift lever) in neutral position
(N), and tilt it to the left (L) halfway.
The R.H. and L.H. tracks rotate in the opposite directions to
each other to make a slow counter-rotation turn to the left.
If the lever is tilted fully, the counter-rotation turn speed in-
creases.
REMARK
When performing counter-rotation turn to the right, set joystick
(steering, directional and gear shift lever) in neutral position
(N), and tilt it to the right (R).
3-178
METHOD FOR TURNING WHILE TRAVELING ON DOWNHILL

METHOD FOR TURNING THE MACHINE GRADUALLY WHILE TRAVELING FOR-
WARD
When gradually turning to the left, tilt joystick (steering, direc-
tional and gear shift lever) forward and tilt it to left (L) halfway.
Cross steering does not occur.
REMARK
When gradually turning to the right, tilt joystick (steering, direc-
tional and gear shift lever) forward and tilt it to right halfway.
Cross steering does not occur.
RECOMMENDED WORKING MODES FOR WORKS

FEATURES OF WORKING MODES
When gear shift mode selector switch (1) is used, gear shift mode can be changed.
Gear shift mode Features
This mode is recommended for normal soil quality and operations, such as digging,
hauling, grading, and leveling.
AUTO The power train is driven with high efficiency, so it is possible to reduce fuel consump-
(Automatic shift mode) tion.
The optimum travel speed is automatically selected and gear shifting is performed
with no shock, so there are no troublesome gear shifting operations.
Use this mode for digging and ripping operations on rough ground or where the load
MAN changes easily.
(Manual shift mode) Use this mode for operations and removing stumps or for side cutting, where deceler-
ation operations are needed.
When operating mode selector switch (2) is used, operating mode can be changed.
Operating mode Features
P Full power is generated, so use this mode for operations on uphill slopes or when
(Power mode) handling large volumes of soil.
Use this mode when it is desired to reduce fuel consumption.
E Use this mode for soil or operations where the shoes tend to slip and where decelera-
tion operations are needed.
(Economy mode)
Use this mode for pushing-down operations and grading operations where power is
not needed.
3-179
Reverse slow mode can be changed with reverse slow mode switch (3).
Reverse slow mode Features
Use this mode for operations on uneven ground or soft rock to improve operator com-
ON
fort when traveling in reverse.
3-180
AA: Standard screen MM: “Mode Select” screen

(1) Gear shift mode selector switch (3) Reverse travel slow mode switch
(2) Operating mode selector switch
For the details of the reverse travel slow mode, see “REVERSE SLOW MODE SWITCH (3-45)”.
RECOMMENDED WORKING MODES

Type of op- Gear shift mode Operating mode Reverse
Soil quality Operating conditions
eration AUTO MAN P E slow mode
Heavy-duty operations,
Normal soil ○ - ○ - -
high productivity desired
Sand, soft Light-duty operations, easi-
Digging, ○ - - ○ -
soil ly slips
hauling
Uneven
ground, Load changes easily - ○ - ○ ○
soft rock
Pushing up Uphill ○ - ○ - -
Pushing down Downhill ○ - - ○ -
Grading, leveling Light-duty operations ○ - - ○ -
Uneven
Ripping ground, Shoes slip easily - ○ - ○ ○
soft rock
Removing stumps, side
- - ○ ○ - -
cutting

WATCH GAUGES
If the power train oil temperature caution lamp lights up during operation, reduce the load and wait for the tem-
perature to go down.
3-181
PERMISSIBLE WATER DEPTH

When operating in water, always keep the bottom of carrier roll-
ers (1) above the surface of the water. Also, be careful that the
hydraulic fan will not come in contact with water. The fan can
be damaged.
After using the machine in the water for a long time, grease the
work equipment and equalizer bar through each grease fitting.
For the greasing method, see “METHOD FOR LUBRICATING
(4-42)”, “METHOD FOR LUBRICATING EQUALIZER BAR
SIDE PIN (4-44)”, and “METHOD FOR LUBRICATING
EQUALIZER BAR CENTER PIN (4-44)”.
PRECAUTIONS FOR LONG-TIME CONTINUOUS TRAVEL OPERATION

Avoid operating the machine at high speed for a long time, oth-
erwise the temperature of lubricating oil sharply rises, and that
can cause oil leakage from the track rollers or final drive and
lower durability.
If there is no way to avoid operating the machine at high speed
for a long time, stop the machine every one hour for 30 minutes
and let the track rollers and final drive cool off before starting
up the machine again.
PRECAUTIONS WHEN TRAVELING ON SLOPES

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

When traveling downhill, move joystick (steering, directional and gear shift lever) into low speed to run engine at
slow speed and travel down slope using the engine brake.
Do not move the joystick (steering, directional and gear shift lever) to NEUTRAL position.
When traveling down hills of more than 15 °, shift down to 1st speed (R1 or F1).
BRAKE ON DOWNHILL
When traveling downhill with the engine brake applied, use the brake as necessary to prevent overrun. Overrun
can cause a failure.
PRECAUTIONS WHEN OPERATING ON SLOPE

Pay attention to 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. This makes the engine stop, so be careful not to let the fuel
level in the fuel tank become too low.
3-182
When working on slopes with an angle of more than 20 °, if the

fuel level on the fuel gauge enters the red range, add fuel im-
mediately.
(A): Red range
(B): Green range
Pay attention to oil level

When operating machine on sloped areas of more than 20 °, fill all appropriate components with oil to H level.
Pay attention to DEF level
Before working on a slope or traveling on a rough ground, check DEF tank and add sufficient amount of DEF as
necessary. If the remaining DEF level becomes low, sudden drop of its level or abnormality in urea SCR system
may be detected. If DEF level caution lamp or DEF system caution lamp lights up in red, move the machine to a
level place immediately and add DEF.
Pay attention to engine speed on slopes
Set the fuel control dial to a medium speed or higher position and prevent the travel speed from increasing with
the decelerator pedal and brake pedal.
Pay attention to stall engine on slopes
If the engine stops while working or traveling on a hill, immediately depress the brake pedal to bring the ma-
chine to a complete stop.
PRECAUTIONS FOR USING BRAKE

Always depress the decelerator pedal to lower the engine speed before actuating the brakes.
Do not place your foot on the brake pedal during operation unless applying the brake.
The following actions cause premature damage to the brakes, so avoid such operations.
• Apply the brake sharply during travel at high idle.
• Operate the brake while the engine is running at high idle in the 1st speed range (F1 or R1). (Machine is
stalled)
DO NOT OPEN DOOR WHILE OPERATING MACHINE

Always keep the door closed when traveling or performing operations.
If the door is open, it may be damaged by obstacles or strong vibration.
DO NOT MODIFY CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE
VIEW
Never install anything which obstructs the view and affects the safety to the glass.
Keep the glass clean and secure the safety for the work.
PRECAUTIONS FOR FLOATING OPERATION

If the blade is operated to FLOAT when the engine is running at low speed or when it is idling, hunting may
occur.
Raise the engine speed when performing FLOAT operation.
3-183
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUC-

TURES
k WARNING
The cab stays create blind spots.
When operating, check carefully that there is no person or
obstacle in the surrounding area.
RECOMMENDED APPLICATIONS
In addition to the following, it is possible to further increase the range of applications by using various attach-
ments.
DOZING WORK
Cut soil and sand and move them forward. When cutting a
slope surface, it is more efficient to always cut from top toward
bottom.
When dozing toward one side only, operate with angled blade.
(Angle dozer, Power angle power tilt dozer)
LEVELING WORK
NOTICE
Avoid leveling work on rocky or stony ground. It can damage the blade.
To finish the ground to a flat surface after digging or piling soil,
put a full load of soil on the front face of the blade and operate
the blade up and down in small movements while traveling for-
ward.
Finally, float the blade travel at low speed in reverse while pull-
ing the blade over the ground surface.
At this time, hold the lever by hand in FLOAT position for at
least 1 second to make sure that it stays in position.
Avoid running over stones or rocks to protect the blade.
3-184
WORKS OF CUTTING INTO HARD OR FROZEN GROUND OR DITCH

For digging and ditch excavation of hard or frozen ground, tilt
the blade. Even hard ground can be dug effectively by a tilted
or angled blade.
WORKS OF FELLING TREES AND REMOVING STUMPS

NOTICE
Do not perform stump removal or other hard work by angling tilting the blade.
For trees with a diameter of 10 to 30 cm, raise the blade high
and push a few times to fell the tree.
Next, travel in reverse, and dig the corner of the blade into the
ground to cut and dig up the roots.
When doing this, never hit the tree at high speed or apply
shock to fell the tree.
METHOD FOR ADJUSTING WORK EQUIPMENT

ADJUST TENSION OF CENTER BRACE
(Straight tilt dozer, straight tilt power pitch dozer, SIGMADOZER, and sigma power pitch dozer)
When transporting the machine, remove the whole set of the work equipment. When assembling again, adjust
the tension of the center brace. If the adjustment is not performed, the bushing at the mounting portion of the
blade and straight frame comes off, and dirt may enter and cause premature wear or damage of the bushing.
For the adjustment method of the center brace, see “ADJUST SHIMS, ADJUST TENSION AT WORK EQUIP-
MENT LINKS (4-36)”.
ADJUST BRACE OF ANGLE BLADE

k WARNING
It is dangerous if the work equipment moves by mistake when the brace is adjusted.
Park the machine on a level ground, set the work equipment in a stable state, and stop the engine. Set
the work equipment lock lever in LOCK position securely.
k CAUTION
The purpose of the brace length adjustment mechanism of the angle blade is to adjust the tilt of the
blade.
If this adjustment is not performed properly, the work equipment may be cracked or broken.
3-185
METHOD FOR ADJUSTING BRACE FOR USING BLADE IN STANDARD POS-

TURE
k CAUTION
Adjust the brace to a proper length.
If the brace is not adjusted to a proper length, an excessive bending stress may be applied to the center
pin, which may be broken.
1. Raise the blade to a height of 400 to 500 mm above the

ground, and put block (A) under the frame to prevent the
blade from lowering.
2. Loosen set bolt (1) of the brace.

Adjust respective lengths (B) of the right and left braces to
the following length.
D65EX: 1127 ± 10 mm
3. Insert a suitable bar into hole (2) of the brace and turn it to
adjust length (B) of the brace.
4. Tighten set bolt (1).
ADJUST SHIMS IN ASSEMBLING WORK EQUIPMENT

• When assembling the work equipment, if the adjustment of the play is not performed properly, excessive
bending stress will be generated at all parts, and this will lead to cracks or breakage.
Adjust the play in adjustment portions (1) to (4) to proper values. For the adjustment method, see “ADJUST
SHIMS, ADJUST TENSION AT WORK EQUIPMENT LINKS (4-36)”.
• When disassembling the machine for transportation, be careful not to lose the shims.
(1) Tilt (2) Lift (3) Center (4) Trunnion
Proper value
0.2 to 0.7 0.2 to 0.7 0.2 to 0.7 0.2 to 1.2
( mm)
Standard shim thickness
5 4 5 10
( mm)
3-186
• Straight tilt dozer

• Straight tilt power pitch dozer
• Sigma dozer
• Sigma power pitch dozer
• Angle dozer
ADJUST ANGLE OF BLADE EDGE

k WARNING
It is dangerous if the work equipment moves by mistake when the angle of blade edge is adjusted.
Set the work equipment in a stable condition, then stop the engine. Set the work equipment lock lever in
LOCK position securely.
The blade cutting edge angle can be adjusted to meet the soil conditions.
METHOD FOR ADJUSTING ANGLE OF BLADE EDGE ON STRAIGHT TILT DOZ-

ER
(Machine with screw adjustment type tilt brace)
Turn the brace with bar handle (1).
• If distance between joints (B) is increased, angle (A) of the
blade edge is increased.
• If distance between joints (B) is decreased, angle (A) of
the blade edge is decreased.
Standard angle (A) of blade edge is 55 °.
Standard distance between joints (B) is as follows;
D65EX: 1150 mm
D65PX: 1146 mm
METHOD FOR ADJUSTING ANGLE OF BLADE EDGE ON ANGLE DOZER

k CAUTION
The angle of the blade edge of the angle dozer blade cannot be adjusted.
If the angle of the blade edge is changed by changing the brace length, an excessive bending stress will
be applied to the center pin, which may be broken.
3-187
Standard blade angle (A) is 55 °.

Standard distance between joints (B) is as follows;
D65EX: 1127 mm
The using range of distance between joints (B) is 1117 to
1137 mm.
METHOD FOR ADJUSTING ANGLE OF BLADE EDGE ON SIGMA DOZER

Turn the brace with bar handle (1).
• If distance between joints (B) is increased, angle (A) of the
blade edge is increased.
• If distance between joints (B) is decreased, angle (A) of
the blade edge is decreased.
Standard angle (A) of blade edge is 46 °.
Standard distance (B) between the joints is 1150 mm.
Angle of
blade
edge Advantages Disadvantages
(A)
• Less soil spills to • Digging resistance
rear of blade. and rolling up resist-
• Dumping performance of soil are high.
Large
ance is high, and • Load pushed by
less soil is brought blade is small
back.
• Soil digging resist- • More soil spills to
ance and rolling-up rear of blade.
resistance are small • Dumping perform-
Small • Load pushed by ance is low, and
blade is large more soil is brought
• Convex portion is cut back.
well.
METHOD FOR ADJUSTING ANGLE OF BLADE EDGE ON POWER ANGLE POW-

ER TILT DOZER
NOTICE
If the distance between joints (B) is lengthened than the standard length, do not perform the full-angling
operation of the blade.
3-188
1. Remove bolts (2) (2 pieces).

2. Remove cover (3).
3. Insert a bar in hole (C) of rod (1) and turn rod (1).
The distance between joints (B) can be adjusted by turning the rod (1).
Angle (A)
Distance be-
of blade Method
tween joints (B)
edge
Install the cover (3) inside out.
Lengthen than Set grease fitting (4) to the position
Increa-
the standard of hole (5) on the cover (3).
ses
length Be sure to set so since lengthening
more can cause damage.
Set grease fitting (4) to the position
Shorten than the Decrea- of hole (6) on the cover (3).
standard length ses Be sure to set so since shortening
more can cause damage.
Set to standard Becomes Set grease fitting (4) to the position
length standard of hole (7) on the cover (3).
4. After adjusting, install cover (3).
5. Install bolts (2) (2 pieces).
Distance between
Angle (A) of joints (B) Use
blade edge
( mm)
Standard: This is suitable for general operations.
456
55 °
This is suitable for digging operations on clay soil or hard soil.
Max.: 58 ° 498 This will improve the removal of the soil from the blade and reduce spillage of
soil over the back of the blade. This is suitable also for dozing operations on
slopes.
3-189
Distance between
Angle (A) of joints (B) Use
blade edge
( mm)
This allows the blade to gather a larger amount of soil and is suitable for haul-
ing operations on soft soil.
Min.: 52 ° 412
This makes it easier for the cutting edge of the blade to dig into the soil, so it is
suitable for operations digging into hard soil.
REMARK
When the maximum cutting angle (blade tilted fully forward) is changed to the minimum cutting angle (blade til-
ted fully backward), there is resistance from the pressure stored in the angle cylinder, so the operating effort
may gradually become heavier.
In this case, turn the starting switch to ON position (you do not need to start the engine), and then cancel the
work equipment lock lever, set the blade control lever in the angling direction, and release the pressure in the
angle cylinder.
ADJUST TILT
METHOD FOR ADJUSTING TILT OF ANGLE DOZER
k WARNING
When adjusting the amount of tilt, it is dangerous if the work equipment is moved by mistake.
Set the work equipment in a stable condition, then stop the engine. Place the work equipment lock lever
in LOCK position securely.
NOTICE
Limit tilt amount (A) to 400 mm.
Adjust tilt amount (A) within 400 mm.
1. Raise the blade to 400 to 500 mm above the ground.

2. Set block (B) under the frame to prevent the blade from
lowering.
3. Stop the engine and set the work equipment lock lever to
LOCK position.
3-190
4. Loosen bolt (1) of the brace, insert a suitable bar into hole
(2) of the brace, and turn it.
When turning the brace with bar, keep the blade above the
ground.
k CAUTION
Do not adjust only either brace.
If the length of only either brace is changed to adjust
the tilt, an excessive bending stress may be applied to
the center pin, which may be broken.
Be sure to lengthen either brace and shorten the oppo-
site one by the same amount.
Right tilt: Make right side shorter, left side longer

Left tilt: Make left side shorter, right side longer
When the tilt is adjusted to the maximum, brace length (C)
is as follows.
(D65EX)
Max. tilt amount: 400 mm
Shortened side: 1070 mm
Lengthened side: 1185 mm
In standard posture: 1127 mm
5. Tighten set bolt (1).
METHOD FOR ANGLING BLADE

(Angle dozers only)
k WARNING
• When adjusting the amount of angling, it is dangerous if the work equipment is moved by mistake.
Set the work equipment in a stable condition, then stop the engine. Place the work equipment lock
lever in LOCK position securely.
• If arm (2) is removed, the blade moves freely. Be careful.
When dozing toward one side only, operate with angled blade.
(I) LEFT ANGLE: 25 °
(E) RIGHT ANGLE: 25 °
3-191
1. Raise the blade to 400 to 500 mm above the ground.

2. Set block (B) under the frame to prevent the blade from
lowering.
3. Stop the engine and set the work equipment lock lever to
LOCK position.
4. Pull out pins (1) on the right and left sides.
5. Remove arm (2) from the frame.

6. Insert arm (2) into any desired bracket (C) on the frame (3
brackets provided on one side) and fasten it with pin (1) so
that it does not slip off.
METHOD FOR ADJUSTING TILT FOR USING BLADE IN ANGLED POSTURE

(Angle dozers only)
Adjust the brace length properly according to the following procedure.
1. Return the blade to the standard posture (non-angled posture).
2. Adjust the tilt to necessary amount.
3. Angle the blade.
TIPS FOR LONGER UNDERCARRIAGE LIFE

Undercarriage life greatly varies depending on operation method, inspection and maintenance.
For most efficient operation, keep the following points in mind.
OPERATION METHOD
• Use a track shoe suitable for soil condition.
For selection of the shoe, consult your Komatsu distributor.
• Do not let the shoe slip during operation.
If the shoe starts slipping, decrease the load to prevent slipping.
• Avoid rapid start, acceleration, stop, or unnecessary high-speed operation or sharp turn.
• Travel as straight as possible. Do not turn only in either direction but turn in both directions evenly. Also,
secure turning radius as large as possible.
3-192
• Clear the travel ground and remove obstacles so that the machine does not ride over large boulders or ob-
stacles.
• On slopes, do not work across the slope surface but work
upward or downward. When stopping the machine on a
slope, direct it up or down.
• If the ground slants to the right or left while the machine is
digging, do not stay there but move back to a level place,
then start digging again.
• If the idler or sprocket floats because of a hard obstacle
during dozing or ripping work, avoid that obstacle, since it
is “difficult to move it”.
METHOD FOR CHECKING AND ADJUSTING

• Adjust the track tension to a proper level.
Check the tension by measuring clearance (A) between
the idler and carrier roller shown in the figure. This clear-
ance should be 20 to 30 mm usually. However, tense a lit-
tle higher for rocky terrain and a little lower for clay land.
Extremely low track tension can cause abnormal vibration
or abnormal wear of sprocket teeth.
For the testing and adjusting method, see “METHOD FOR
CHECKING AND ADJUSTING TRACK TENSION”.
• Check the idler and rollers for oil leakage and loose bolts
and nuts.
Repair any abnormality immediately.
• Check a clearance (B) between front idler guide plate (1)
and track frame (2).
As clearance (B) becomes larger, it can cause the front id-
ler to sway sideways and cause the track shoe to jump off
rollers.
For the testing and adjusting method, see “METHOD FOR
ADJUSTING IDLER CLEARANCE”.
METHOD FOR CHECKING AND REPAIRING

Frequent inspection and prompt repair will reduce repair costs.
The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per-
form periodical inspection and contact the Komatsu distributor in your area when machine has approached re-
pairable limits and reversing limits.
3-193
METHOD FOR MEASURE LINK PITCH

1. Put a wooden block, etc. between the track shoe and
sprocket to eliminate the sag of the track.
2. Measure length (L) of 4 link pitches in a straight portion at

least 2 links apart from master link (A).
1/4 of the measured value is the link pitch.
Standard link pitch (P): 203 mm
Turning limit link pitch of bushing: 206 mm
The master link has no link window.
REMARK
The decimal portion of the measured value of link pitch
may be different from standard link pitch (P), depending on
the measurement accuracy and machining tolerance, even
if the track is not worn. Do not judge the track is worn by
only the value measured now, but judge by the trend of the
later measured values.
METHOD FOR MEASURE GROUSER HEIGHT

Eliminate the sag of the track, and measure at the center of the
track.
Standard dimension (h): 65 mm
Repairable limit: 25 mm
3-194
METHOD FOR MEASURING TRACK ROLLER DIAMETER

1. Measure the link tread (dimension C) as shown in the fig-
ure.
2. Stop the machine at a position where the link tread, at
which dimension C was measured, is perfectly in contact
with the roller tread.
3. Measure dimension B.
4. Calculate outside diameter of the tread (dimension A).
A = (B - C) x 2
• Standard dimension (h): 210 mm
• Repairable limit: 172 mm
METHOD FOR PARKING MACHINE

k WARNING
• Avoid a sudden stop. Stop the machine gradually.
• Place the machine on a firm, level ground.
Do not park the machine on a slope.
If it is unavoidably necessary to park the machine on a
slope, place parking brake lever (4) in LOCK position
and insert blocks underneath the track shoes to pre-
vent the machine from moving. As an additional safety
measure, thrust the work equipment into the ground.
• If the work equipment control levers are touched by
mistake, the work equipment may move suddenly
causing a serious accident. Before leaving the opera-
tor's seat, always secure work equipment lock lever (7)
in LOCK position.
1. Depress brake pedal (1) to apply the brake.

NOTICE
If the brake pedal is depressed when the engine speed
or travel speed is high, the brake disc may make a
slipping sound. When depressing the brake pedal,
usually depress decelerator pedal (2) to reduce the en-
gine speed and machine travel speed.
3-195
2. Set joystick (steering, directional and gear shift lever) (3) to

N (Neutral) position.
3. Set parking brake lever (4) to LOCK position (L).
4. Set blade control lever (5) to LOWER position (C) and low-
er the blade to the ground.
5. Return blade control lever (5) to HOLD position (B).
6. Set ripper control lever (6) to LOWER position (c) and low-
er the ripper to the ground.
7. Return blade control lever (6) to HOLD position (b).
8. Set work equipment lock lever (7) to LOCK position (L).
To secure a sufficient space to get off the machine, move the operator's seat and console backward if they are
positioned forward.
3-196
METHOD FOR CHECKING AFTER FINISHING WORK

CHECKS BEFORE STOPPING ENGINE
On the machine monitor, check the engine coolant tempera-
ture, hydraulic oil temperature, power train oil temperature, en-
gine oil pressure, remaining fuel level, and remaining DEF lev-
el.
CHECKS AFTER STOPPING ENGINE

1. Perform walk-around check for oil or coolant leakage and for abnormality in work equipment, exterior parts,
and undercarriage.
If oil or coolant leakage or any abnormality is detected, repair it.
2. Check DEF tank, pump, injector, hose, and joint for leakage.
If any abnormality is found, ask your Komatsu distributor for repair.
3. Fill the fuel tank.
4. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
5. Remove any mud affixed to the undercarriage.
LOCK
The following sections are lockable to prevent vandalism.
Places that can be locked with the starting switch key.
• Top cover at front of chassis (1)
• Toolbox storage cover (2)
• Cab door opener (3) (right and left) (Machine equipped
with cab)
• Battery inspection cover (rear) (4)
• Battery inspection cover (front) (5)
• Engine side cover (6) (right and left)
• Reservoir tank inspection cover (7)
• Power train oil level inspection cover (8)
• Hydraulic tank oil filler cap (9)
• DEF tank filler port cover (10)
• Inspection cover for fuel tank drain valve (11)
3-197
Places locked with special key

• Fuel tank fuel filler cap (12)
REMARK
If padlock (A) is to be used, it is recommended to use the type
that has the cover to protect the key hole.
METHOD FOR OPENING AND CLOSING CAP WITH LOCK

PROCEDURE FOR OPENING CAP WITH LOCK
1. Insert the key into the key slot.
Make sure that you have inserted the key fully (1) before
turning it.
If the key is turned when only partially inserted, it may
break.
Position (L) : LOCK
(F) : OPEN position
(A) : Working angle of key 180 °
(B): 45 °
2. Turn the key counterclockwise.

3. Align the rotor groove with match mark (2) of the cap.
4. Turn the cap slowly.
If a “click” is heard, the cap is unlocked and can be re-
moved.
3-198
PROCEDURE FOR CLOSING CAP WITH LOCK

1. Screw in the cap until it becomes tight, then insert the key into the key slot.
2. Turn the starting switch key to “LOCK” position, then remove the key.
METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP

PROCEDURES FOR OPENING FUEL FILLER PORT CAP
1. Raise lever (1) in the direction (a).
2. Turn lever (1) in direction (c) (counterclockwise) approxi-
mately 35 °.
The cap stops at the stopper, and you can open it.
PROCEDURES FOR CLOSING FUEL FILLER PORT CAP

1. After turning lever (1) in the (c) direction (counterclock-
wise), keep it in that position and fit the cap.
2. Turn lever (1) in the (d) direction (clockwise) until it stops
at the stopper, and then tilt it in the (b) direction.
METHOD FOR OPENING AND CLOSING COVER WITH LOCK

METHOD FOR OPENING COVER WITH LOCK
1. Insert the key into the key slot.
2. Turn the key counterclockwise and open the cover by pulling the cover handle.
• Cab door opener
Position (A): OPEN
Position (B): CLOSE (LOCK)
3-199
• Cover other than cab door opener

Position (A): OPEN
METHOD FOR LOCKING COVER WITH LOCK

1. Close the cover and insert the key into the key slot.
2. Turn the starting switch key to CLOSE position (B), then remove the key.
METHOD FOR OPENING AND CLOSING DEF TANK FILLER CAP COVER
k CAUTION
• When opening or closing the DEF tank filler cap cover, place the machine on a level place, lower the
work equipment to the ground, stop the engine, then perform the operation.
• When opening it, do not release the handle until the stay is set in the lock position securely.
• When closing it, hold the handle securely since the DEF tank filler cap cover may move down be-
cause of its own weight.
If it is not locked, it may close suddenly because of wind, etc.
METHOD FOR OPENING DEF TANK FILLER CAP COVER

1. Insert the key into key slot (1).
2. Turn the key counterclockwise and remove it.

Position (A): OPEN
3. Push in the lock cancel button of knob (2) and unlock.
4. Pull handle (3) and open DEF tank filler port cover.
METHOD FOR LOCKING DEF TANK FILLER CAP COVER

1. Close the DEF tank filler port cover.
2. Lower knob (2) and lock the cover.
3. Insert the key into key slot (1).
4. Turn the starting switch key to “CLOSE” position (B), then remove the key.
3-200
Position (A): OPEN

METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT CAP
METHOD FOR OPENING DEF TANK FILLER PORT CAP
1. Open DEF tank filler port cover.
2. Turn DEF tank filler port cap (1) counterclockwise (O) and
open it.
Direction (O): Open
Direction (C): Close
When the cap (1) does not open easily, open DEF tank filler port cap (1) by using the special tool.
1. Prepare tool (2).
2. Hold cap (1) with tool (2).
3. Hold tool (2) tightly, turn it counterclockwise.
METHOD FOR CLOSING DEF TANK FILLER PORT CAP

Close DEF tank filler port cap (1) by turning it clockwise (C).
Direction of (O): Open
Direction of (C): Close
3-201
HANDLE AIR CONDITIONER OPERATION
HANDLE AIR CONDITIONER

NOTICE
• When performing running-in of the air conditioner, always start with the engine running at low
speed. Never start the air conditioner when the engine is running at high speed. It will cause failure
of the air conditioner.
• If water gets into the control panel or sunlight sensor, it may lead to unexpected failure, take care
not to let water get on these parts. In addition, never bring any open flame near them.
• For the auto function of the air conditioner to work properly, always keep the sunlight sensor clean
and do not leave anything around the sunlight sensor that may interfere with its sensor function.
When the air conditioner is not used every day, to prevent loss
of the film of oil at various parts, run the air conditioner with the
engine at low speed from time to time and perform cooling or
dry heating for several minutes.
When the temperature inside the cab is low, the air conditioner
may not work. In this case, circulate recirculation air to warm
the inside of the cab. After that, turn the air conditioner switch
ON, the air conditioner will work.
If any abnormality is detected in any equipment or sensor used
on the air conditioner, the air conditioner system caution lamp
lights up on the monitor screen. If the air conditioner system
caution lamp lights up, ask your Komatsu distributor for inspection and repair.
Ventilation
• When running the air conditioner for a long time, turn the lever to FRESH position once an hour to perform
ventilation and cooling.
• If you smoke when the air conditioner is on, the smoke may hurt your eyes. In such case, open the window
and turn the lever to FRESH for a while for ventilation and driving smoke out.
Temperature control
For reasons of health, the optimum setting for cooling is considered to be when it feels slightly cool (5 to 6 °C
lower than the ambient temperature) when you enter the cab.
Be careful to select the appropriate temperature.
If the cold air form the air conditioner blows directly against the machine monitor, water may condense on the
machine monitor screen. In this case, change the angle of the vent.
3-202
OPERATION HANDLE AIR CONDITIONER
EXPLANATION OF AIR CONDITIONER EQUIPMENT
(1) Sunlight sensor (6) Vent selector switch

(2) Display monitor (7) FRESH/RECIRC air selector switch
(3) Auto switch (8) Fan switch
(4) Air conditioner switch (9) Temperature control switch
(5) OFF switch
OFF SWITCH
This switch is used for stopping the fan and air conditioner.
REMARK
Even if this OFF switch is pressed, the monitor screen does not
switch to the air conditioner adjustment screen.
FAN SWITCH
You can adjust the air flow by using the fan switch.
The air flow can be adjusted to 6 levels.
• Press the △ switch to increase the air flow; press the ▽
switch to decrease the air flow.
• During auto operation, the air flow is automatically adjust-
ed.
3-203
Monitor display and air flow

Monitor display Air flow rate
Air flow "low"
Air flow "medium 1"
Air flow "medium 2"
Air flow "medium 3"
Air flow "medium 4"
Air flow "high"
TEMPERATURE SET SWITCH

Use the temperature set switch to adjust the temperature inside
the cab. The temperature can be set between 18°C and 32°C.
• Press the △ switch to raise the set temperature; press the
▽ switch to lower the set temperature.
The set temperature is indicated on the display monitor.
• The temperature is generally set at 25°C.
• The temperature can be set in stages of 0.5°C.
Monitor display and function

Monitor display (°C) Set temperature
18.0 Max. cooling
18.5 to 31.5 Adjusts temperature inside cab to set temperature
32.0 Max. heating
REMARK
If the mode is set to auto mode and the temperature setting is set to 18.0°C or 32.0°C, the air flow from the fan
is always set to HIGH and does not change even when the temperature reaches the set value.
VENT SELECTOR SWITCH

The vent selector switch is used to select the vents.
• When vent selector switch is pressed, the LC display on
the monitor display switches and air blows out from the
vents displayed.
• During automatic operation, the vents are automatically
selected.
3-204
(A1): Face vent (right and left 1 place)

(A2): Rear vent (2 places)
(A3): Front vent (2 place)
(B): Foot vent (2 place)
(C1): Door glass vent (right and left 1 places)
(C2): Front window glass vent (1 place)
Air blows out from the vents marked with ○.
Vent
LCD display Air vent mode Remarks
(A) (B) (C)
Front and rear vents ○ -
Front, rear, and foot vents ○ ○ -
Foot vent ○ -
Foot vent
○ Not selected in auto mode
Defroster vent
Defroster vent ○ Not selected in auto mode
3-205
AUTO SWITCH
Use the auto switch for automatic selection of the air flow,
vents, and air source (FRESH/RECIRC) according to the set
temperature.
• Press this switch, then use temperature control switch (1)
to set the temperature, and run the air conditioner under
automatic control.
• When switching from automatic operation to manual oper-
ation, it is possible to use the switches to select the vents
and air source (FRESH/RECIRC).
REMARK
When Auto Mode is selected, if the set temperature is set to
18.0 °C or 32.0 °C, the air flow is always set to “High”, but this
is not a problem.
FRESH/RECIRC AIR SELECTOR SWITCH

Use FRESH/RECIRC air selector switch to switch the air
source between recirculation of the air inside the cab and in-
take of fresh air from the outside.
During automatic operation, the selection of inside air (RE-
CIRC) and outside air (FRESH) is performed automatically.
RECIRC
Outside air is shut off and only air inside the cab is circulated.
Use this setting to perform rapid cooling of the cab or when
outside air is dirty.
FRESH
Outside air is taken into the cab.
Use this setting to take in fresh air or to demist the window glass.
DISPLAY MONITOR
This monitor display indicates the status of temperature setting
(a), air flow (b), and vents (c).
3-206
When OFF switch (1) is pressed, the display of temperature

setting (a) and air flow (b) goes out, and operation stops.
AIR CONDITIONER SWITCH

Use air conditioner switch for turning the air conditioner (cool-
ing, dry heating) ON or OFF.
• Press air conditioner switch when the fan is operating
(when display (b) is shown on the display monitor). The air
conditioner is switched ON and starts to work. Press the
switch again to stop the air conditioner.
• Air conditioner cannot be operated while the fan is stop-
ped.
SUNLIGHT SENSOR
Sunlight sensor automatically adjusts the flow of air from the
vents to match the strength of the sun's rays. In addition, it au-
tomatically detects changes in the temperature inside the cab
caused by changes in the strength of the sun's rays beforehand
and automatically adjusts the temperature.
METHOD FOR OPERATING AIR CONDITIONER

The air conditioner can be operated automatically or manually. Select the method of operation as desired.
3-207
METHOD FOR AUTOMATIC OPERATION

1. Turn auto switch (1) ON.
Set temperature (a) and air flow (b) are displayed.
2. Use temperature control switch (2) to set to the desired

temperature.
The air flow, combination of vents, and selection of fresh or
recirculated air is automatically selected according to the
set temperature, and the air conditioner is operated auto-
matically to provide the set temperature.
REMARK
When vent display monitor (c) displays (d) or (e), and engine
coolant temperature is low, the air flow is automatically limited
to prevent cold air from blowing out.
3-208
METHOD FOR STOPPING AUTOMATIC OPERATION

Press OFF switch (1).
The air conditioner stops.
METHOD FOR MANUAL OPERATION

1. Press fan switch (1) and adjust the air flow.
When doing this, check that temperature setting (a) and air
flow (b) are displayed.
3-209
2. Turn air conditioner switch (2) ON.
3. Press temperature control switch (3) to adjust the tempera-

ture in the cab.
4. Press vent selector switch (4) and select the desired vents.
When this is done, the display for vent (c) of the monitor
changes according to the selection.
5. Press FRESH/RECIRC selector switch (5) and select recir-

culation of the air inside the cab (RECIRC) or intake of
fresh air from outside (FRESH).
3-210
METHOD FOR STOPPING MANUAL OPERATION

Press OFF switch (1).
The air conditioner stops.
METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET
To operate with cold air blowing to the face and warm air blowing to the feet, set as follows.
3-211
2. Press vent selector switch (2) and set the vent display on
the monitor to the display shown in the figure.
3. Turn air conditioner switch (3) ON.
3-212
4. Adjust fan switch (1), temperature control switch (4) and

FRESH/RECIRC selector switch (5) to the desired posi-
tions.
METHOD FOR OPERATING DEFROSTER

3-213
2. Press vent selector switch (2) and set the vent display on
the display monitor to (f) or (g) as shown in the figure.
3. Press FRESH/RECIRC selector switch (3) and set it to

FRESH mode.
4. Press temperature control switch (4) and set temperature

on the monitor to “32.0” of maximum heating.
5. Adjust the vents so that the air blows onto the window
glass.
3-214
6. When operating in the rainy season or when it is desired to

remove the mist from the window glass or to dehumidify
the air, turn air conditioner switch (5) ON.
3-215
HANDLING RADIO OPERATION
HANDLING RADIO
• To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera-
tion.
• If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them.
• Do not wipe the display or buttons with solvent such as benzene or thinner. Wipe with a dry soft cloth.
• When the battery disconnect switch is turned to OFF position or the power for the machine is turned off for
the replacement of the battery, the clock may be initialized. In such a case, set it again.
For handling of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-102)”.
EXPLANATION OF RADIO EQUIPMENT
(1) Power button (5) Preset button

(2) Band/AUX selector button (6) Display selector button
(3) Volume control button (7) Sound control button
(4) Tuning/time adjustment button (8) Display
POWER BUTTON
Press the power button to supply the power to the radio and the frequency is shown on display. As long as AUX
is selected, display indicates AUX on it. Press the button again to turn the power off.
BAND/AUX SELECTOR BUTTON

Press band/AUX selector button to select the desired band or AUX.
Each time the button is pressed, the band changes FM → AM → AUX → FM...
VOLUME CONTROL BUTTON

Use the volume control button to control the volume.
Press the △ button, and the volume increases. Press the ▽ button, and the volume decreases. The range for
the volume is 0 to 32.
Hold down this button, and you can change the volume continuously.
TUNING/TIME ADJUSTMENT BUTTON

Use the tuning/time adjustment button to select frequency and step for sound adjustment and to adjust time.
PRESET BUTTON
If you register desired stations to the preset button beforehand, you can select each station by touching this but-
ton once.
3-216
OPERATION HANDLING RADIO
It is possible to preset 6 stations each for both AM and FM.
DISPLAY SELECTOR BUTTON

Use the display selector button to change frequency and clock shown on the display.
Each time you press this button, frequency, clock and band are shown on the display in this order.
If 1.5 seconds passes while a band is shown, a frequency will be displayed.
As long as AUX is selected, this button alternately switches the display between AUX and the clock.
SOUND CONTROL BUTTON

Press the sound control button, and the sound adjustment is ready.
Each time this button is pressed, BAL (Balance), TRE (Treble) and BAS (Bass) will be selected in this order.
If this button is pressed while BAS is displayed, the sound adjustment will be cancelled.
DISPLAY
(A): Band name, “AUX”, frequency, clock and other character/
numeric information are displayed.
(B): Frequencies are displayed at steps of 50 kHz in certain
areas.
(C): Lights up when a stereo broadcasting is heard while a FM
station is selected.
(D): Lights up at the time of balance adjustment in the sound
adjusting condition.
(E): Lights up at the time of treble adjustment in the sound ad-
justing condition.
(F): Lights up at the time of bass adjustment in the sound adjusting condition.
AUX
NOTICE
• A stereo miniature plug can be connected.
Read the instruction manual of the equipment to connect carefully.
• As a power source for the equipment to connect, use the battery attached to that equipment.
If you use an electric power supply installed to the machine, the noise may occur.
• The noise may occur if you pull out the input plug when AUX is selected, or if you push in or pull
out the plugs of the equipment to connect.
You can hear the sound through the speaker of the machine when you connect a commercially available porta-
ble audio equipment to the machine.
3-217
1. Open cap (a).

2. Connect a portable audio equipment by using an commer-
cially available audio cable.
3. Press the band/AUX selector button and select AUX.
METHOD FOR CONTROLLING RADIO

METHOD FOR ADJUSTING FREQUENCY
1. Press band/AUX selector button (1) and select FM or AM.
2. Press tuning/time adjustment button (2) to adjust the fre-
quency.
• Press the △ button, and the frequency increases;
press the ▽ button, and the frequency decreases.
• Hold down the △ button, and the frequency increases
continuously; hold down the ▽ button, and the fre-
quency decreases continuously.
• Hold down the △ button and release it, then the fre-
quency increases continuously. Hold down the ▽ but-
ton and release it, them the frequency decreases continuously as an auto seek.
When a proper frequency is picked up, the tuning automatically stops.
METHOD FOR ADJUSTING FREQUENCY (AUTO PRESETTING)

2. Hold down sound control button (2).
When a proper frequency is picked up, it is automatically registered to preset memories 1 to 6.
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OPERATION HANDLING RADIO
METHOD FOR CALLING PRESET

2. Press one of 1 to 6 of preset button (2).
The frequency registered in the preset number of the pressed button is called up and received.
“Example”
While a frequency is displayed, press button 1 of preset button (2), and the preset number “P-1” appears on the
display.
The preset number is shown for 0.5 seconds, and then the frequency is displayed.
METHOD FOR REGISTERING PRESET

Hold down one of 1 to 6 of preset button (1) while listening to
the radio.
The currently received frequency is registered to the preset number corresponding to the pressed button.
“Example”
While a frequency is displayed, keep pressing button 1 of preset button (1), and the preset number “P-1” is dis-
played.
After the preset number flashes 3 times, the frequency is displayed and then registered to preset number “P-1”.
METHOD FOR ADJUSTING SOUND BALANCE

1. Press sound control button (1) to light up “BAL” on the dis-
play.
You can adjust the sound (balance).
2. Press tuning/time adjustment button (2) to adjust the
sound (balance).
• Press the △ button, and the speaker output on the R
side increases by 1. (R1 to R7)
• Press the ▽ button, and the speaker output on the L
side increases by 1. (L1 to L7)
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METHOD FOR ADJUSTING HIGH REGISTER RANGE (TREBLE)

1. Press sound control button (1) to light up “TRE” on the dis-
play.
You can adjust the high register range (treble) of the
sound.
2. Press tuning/time adjustment button (2) to adjust the high
register range (treble).
• Press the △ button, and the high register range (tre-
ble) level increases by 1. (Maximum + 7)
• Press the ▽ button, and the high register range (tre-
ble) level decreases by 1. (Minimum - 7)
METHOD FOR ADJUSTING LOW REGISTER RANGE (BASS)

1. Press sound control button (1) to light up “BAS” on the dis-
play.
You can adjust the low register range (bass) of the sound.
2. Press tuning/time adjustment button (2) to adjust the low
register range (bass).
• Press the △ button, and the low register range (bass)
level increases by 1. (Maximum + 7)
• Press the ▽ button, and the low register range (bass)
level decreases by 1. (Minimum - 7)
METHOD FOR ADJUSTING CLOCK

1. Press display selector button (1) to display the clock.
2. Hold down display selector button (1) to flash the “HOUR”
display portion.
You can adjust the hour.
3. Press tuning/time adjustment button (2) to adjust the hour.
• If you press △ button, “HOUR” display increases by 1.
• If you press ▽ button, “HOUR” display decreases by
1.
4. Press display selector button (1) to flash the “MINUTE” dis-
play portion.
You can adjust the minute.
5. Press tuning/time adjustment button (2) to adjust the minute.
• If you press △ button, “MINUTE” display increases by 1.
• If you press ▽ button, “MINUTE” display decreases by 1.
6. Press display selector button (1) to cancel time adjustment.
The screen returns to clock display.
ANTENNA
NOTICE
When transporting the machine or when parking it in a garage, direct the antenna down and make sure
that it does not contact anything.
3-220
OPERATION TRANSPORTATION
TRANSPORTATION
TRAVEL ON ROAD
When traveling on paved roads, use flat shoes to protect their surface.
If the flat track shoes cannot be prepared, always place boards to protect the road surface even when traveling
a short distance.
Note that the asphalt road becomes soft in summer.
PRECAUTIONS FOR TRANSPORTING MACHINE

When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
When transporting the machine, choose the transportation method in reference to the weight and dimensions of
machine.
Note that the machine “SPECIFICATIONS” (weight and dimensions) vary depending on the kind of track shoes,
blade, or other equipment.
METHOD FOR REMOVING WORK EQUIPMENT

If there is any pressure remaining in the tilt piping after the work equipment has been removed, it may be diffi-
cult to remove the quick coupler of the tilt hose. Remove according to the following procedure.
1. Lower the blade to the ground and set it in parallel with the
ground surface.
REMARK
When the blade is tilted, internal pressure is applied to the
tilt piping. Set the blade in parallel with the ground surface.
2. Remove quick coupler (1).

3. Remove the work equipment assembly.
4. Remove R.H. and L.H. trunnions (2).

(D65PX, D65WX)
REMARK
• For D65PX and D65WX, remove right and left trunn-
ions (2).
• For D65EX, R.H. and L.H. trunnions (2) do not need to
be removed since width (A) including them is less than
3 m.
5. Tie the tilt hose with a band to prevent it from being dam-
aged.
3-221
TRANSPORTATION OPERATION
LOADING AND UNLOADING WITH TRAILER

k WARNING
• Since loading and unloading of the machine is dangerous, be extremely careful.
• When loading or unloading the machine, lower the engine speed, set the speed range to the 1st, and
operate slowly.
• Use ramps with ample width, length, thickness, and strength and install them with a maximum slope
of 15°.
If the ramps deflect much, reinforce them with blocks, etc.
• Load the machine on a flat and firm ground.
Secure sufficient distance from the road edge.
• Remove mud, etc. from the undercarriage of the machine so that the machine does not slip side-
ways on the ramps.
In addition, remove water, snow, ice, grease, oil, etc. from the ramps.
• Never correct your steering on the ramps. There is danger that the machine may tip over.
If necessary, drive off the ramps or back on to the trailer and correct the direction.
• The center of gravity of the machine shifts suddenly at the joint between the ramps and the trailer,
and it is dangerous that the machine loses its balance. Pass slowly.
When loading or unloading the machine, be sure to use ramps or platform, and follow the procedure shown be-
low.
PROCEDURES FOR LOADING MACHINE

Load on a firm and level ground.
1. Park a trailer on a firm and level ground.
Maintain a safe distance from the road shoulder
2. Apply the brake of the trailer securely.
3. Set chocks (1) to the tires to secure the trailer.
4. Install ramps (2).
Set gap (3) between ramps (2) to match the distance be-
tween the right and left tracks, and keep angle (4) to a
maximum of 15 °.
If ramps (2) bend appreciably under the weight of the ma-
chine, put wooden block (5) under the ramps to support
them.
5. Start the engine.
In a cold weather, perform an engine warm-up operation, referring to “METHOD FOR STARTING ENGINE
IN COLD WEATHER (3-160)”.
6. When transporting the machine with the work equipment installed to it, raise the work equipment.
1) Set the work equipment lock lever (6) to FREE posi-
tion (F).
2) Operate the blade control lever and raise the work
equipment.
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7. Set the parking brake lever (7) in FREE position (F).

8. Use the 1st gear speed and run the engine at low idle.
9. Set the travel direction toward the ramps and drive slowly.
The center of gravity of the machine shifts suddenly at the
joint between the ramps and the trailer, and the machine is
unbalanced and becomes unstable. Drive the machine
carefully and slowly.
10. Stop the machine at the specified position on the trailer.
METHOD FOR SECURING MACHINE

NOTICE
Be sure to lower the car radio antenna to the stow position.
After loading the machine onto a trailer, secure the machine as follows.
1. Lower the work equipment slowly.
(When transporting with work equipment installed)
2. Set the work equipment lock lever (1) securely to LOCK
position (L).
3. Set the parking brake lever (2) securely to LOCK position

(L).
4. Stop the engine, then remove the key from the starting switch.
5. Tie one end of each chain or wire rope of appropriate strength to the tie-down holes as shown in the figure,
and secure the machine.
Secure the machine so that it will not move during transportation.
In particular, fix the machine securely to prevent it from slipping sideways.
Keep the lifting tools off the tracks.
3-223
Front of the machine

When no front work equipment is attached
When front work equipment is attached (PAT specification)
Rear of the machine

When a drawbar is equipped
3-224
When a hitch is equipped
When a counterweight-hitch is equipped
When a ripper is equipped
PROCEDURES FOR UNLOADING MACHINE

Perform unloading of the machine on a firm and level ground.
1. Park a trailer on a firm and level ground.
Maintain a safe distance from the road shoulder
2. Apply the brake of the trailer securely.
3. Set chocks (1) to the tires to secure the trailer.
4. Install ramps (2).
Set gap (3) between ramps (2) to match the distance be-
tween the right and left tracks, and keep angle (4) to a
maximum of 15 °.
If ramps (2) bend appreciably under the weight of the ma-
chine, put wooden block (5) under the ramps to support
them.
5. Remove the chains and wire ropes fastening the machine.
In a cold weather, perform an engine warm-up operation, referring to “METHOD FOR STARTING ENGINE
IN COLD WEATHER (3-160)”.
7. When transporting the machine with the work equipment installed to it, raise the work equipment.
3-225
1) Set the work equipment lock lever (6) to FREE posi-

tion (F).
2) Operate the blade control lever and raise the work
equipment.
8. Place the parking brake lever (7) in FREE position (F).

9. Set the transmission in the 1st gear speed and run the en-
gine at low idle.
10. Set the travel direction toward the ramps and drive slowly.
The center of gravity of the machine shifts suddenly at the
joint between the ramps and the trailer, and the machine is
unbalanced and becomes unstable. Drive the machine
carefully and slowly.
Drive down the ramps slowly and carefully until the ma-
chine leaves the ramps perfectly.
METHOD FOR LIFTING MACHINE

k WARNING
• The person using the crane to perform lifting operations must be a qualified crane operator.
• Never perform lifting operation if any person is on the machine being lifted.
• Always use a wire rope that has ample strength for the weight of the machine being lifted.
• Keep the machine horizontal while lifting it.
• When performing lifting operations, place the work equipment lock lever and parking brake lever in
LOCK position to prevent the machine or work equipment from moving unexpectedly.
• Never enter the area under or around a lifted machine.
• There is a danger that the machine loses its balance.
Use the procedure below to set the machine in the proper posture and use the lifting equipment
when lifting the machine.
NOTICE
This method of lifting applies to the standard specification machine.
The method of lifting differs depending on the attachments and options installed.
For details of the procedure for machines that are not the standard specification, consult your Komatsu
distributor.
For the weight, see “SPECIFICATIONS (5-2)”.
When lifting the machine, stop it on a level place, then lift it as follows.
3-226
Lifting points of machine
• Hang the front wire ropes to each cylinder support (1) on the right and left sides.
• Fit the wire ropes at the rear to both left and the right pivot shafts (2).
For machine equipped with ripper
• Hang the front wire ropes to each cylinder support (1) on the right and left sides.
• Fit the wire ropes at the center to both left and the right pivot shafts (2).
• Hang the rear wire rope to ripper beam (3).
1. Stop the engine.
3-227
2. Set the parking brake lever securely to LOCK position (L).
3. Set the work equipment lock lever securely to LOCK posi-

tion (L).
4. Install wire ropes and slings matching to the weight of the
machine.
NOTICE
• Use protectors, etc. so that the wire ropes will not
be broken at sharp edges or narrow places.
• When using a spreader bar, select an ample width
to prevent contact with the machine.
5. Just before slinging the machine, lift it off the ground by
100 to 200 mm while it is being set.
6. Check that the wire ropes are free of looseness and the machine is kept on a level state.
7. Sling the machine slowly.
3-228
OPERATION COLD WEATHER OPERATION
COLD WEATHER OPERATION

COLD WEATHER OPERATION INFORMATION
If the ambient temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze.
Follow the instructions described as follows.
FUEL AND LUBRICANTS

Change fuel and oil with ones of low viscosity for all components.
For the details of specified viscosity, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-6)”.
COOLANT
k WARNING
• Coolant is toxic. Be careful not to get it into your eyes or on your skin.If it should get into your eyes
or on your skin, wash it off with large amounts of fresh water and see a doctor immediately.
• When handling the cooling water containing coolant that has been drained during changing the
coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to
perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the
ground surface.
NOTICE
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC) as coolant.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
For details on the coolant change interval and the density of Non-Amine Engine Coolant (AF-NAC), see “METH-
OD FOR CLEANING INSIDE OF COOLING SYSTEM (4-19)”.
DEF
NOTICE
• DEF freezes at –11 °C.
If DEF in DEF tank freezes, it may expand and the devices in the tank may be broken or the parts
may be affected. Add DEF to the specified amount for cold weather (below the level of when DEF
may freeze).
For the specified amount of DEF, see “METHOD FOR CHECKING DEF LEVEL, ADDING DEF (3-141)”.
• If DEF or the machine equipped with DEF system cannot be stored at the outside temperature is
lower than –11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF,
and keep it in the condition free from freezing.
BATTERY
k WARNING
• Battery generates flammable gas. Never bring any open flame near fuel.
• Battery electrolyte is dangerous object. If it gets in your eyes or on your skin, wash it off with a
large amount of water and consult a doctor.
• Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
• If the battery electrolyte is frozen, do not charge the battery or start the engine with a different pow-
er source. There is danger that the battery may explode.
• Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground sur-
face.
3-229
COLD WEATHER OPERATION OPERATION
When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging
rate as close as possible to 100%. Insulate it against cold temperature to ensure that the machine can be
started easily in the next morning.
REMARK
Measure the gravity of the electrolyte and calculate the charging rate from the following conversion table.
Electrolyte Temper-
ature 20 °C 0 °C –10 °C –20 °C
Charging Rate (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
• When the ambient temperature is low, the capacity of the battery considerably drops. Cover it, or remove it
from the machine to place it in the warm place. Restore it again before the operation.
• If the electrolyte level is low, add distilled water in the morning before beginning the work. Do not add water
after the day's work to prevent diluted electrolyte in the battery from freezing during the night.
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER

k WARNING
Performing idling of the tracks is dangerous, stay well away from the tracks.
To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, observe the following precautions.
• Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rods clean
to prevent damage to the seal caused by mud, dirt, or drops of water on the rod from getting inside the seal.
• Place the machine on a firm, dry ground.
If this is impossible, park the machine on boards.
The boards prevent the tracks from freezing to the ground, and allow the machine to move the next morn-
ing.
• Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
• Fill up the fuel tank. This minimizes moisture condensation in the tank when the temperature drops.
• In cold weather condition, add DEF to the defined level strictly. If adding more than the defined level, it may
expand to break the devices in the tank when it freezes.
If DEF tank level is lower than the defined level for the cold weather, DEF may freeze easily to damage the
parts in DEF system. If the filler cap freezes, defreeze and open.
• After operation in water or mud, remove water from undercarriage as described below to extend undercar-
riage service life.
• Do not leave the machine running idle for a long time. The inside of KCCV and blowby piping may freeze
solid and block the piping.
To prevent freeze, stop the engine or, if it is necessary to run the engine at idle, apply the load from time to
time.
• Do not continue low-load operation . If continuous low-load operation is performed, operate the machine
with load (warm-up operation) before stop the engine.
AFTER COLD WEATHER SEASON

When the season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “METHOD
FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
3-230
OPERATION COLD WEATHER OPERATION
If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated
freeze, ask your Komatsu distributor to inspect.
3-231
PRECAUTIONS FOR LONG-TERM STORAGE OPERATION
PRECAUTIONS FOR LONG-TERM STORAGE

PREPARATION FOR LONG-TERM STORAGE
When putting the machine in long-term storage (more than one month), store it as follows.
• Clean and wash all parts of the machine and store it indoors. If the machine has to be stored outdoors,
place it on a level ground and cover it with tarpaulins.
• Fill up the fuel tank. This prevents dew condensation.
• Grease the machine and change the oil before storage.
• Fill up DEF tank (Except cold weather condition). Urea deposits caused by internal drying can be preven-
ted. Urea deposits may cause failures in component operation.
When storing the machine in a place where the temperature is lower than –11 °C , however, add DEF to the
specified amount for cold weather (below the level of when DEF may freeze).
• Apply thin film of grease to metal surface of the hydraulic piston rods and the idler adjusting rods.
• After turning the starting switch to OFF position, turn the battery disconnect switch key to OFF position and
pull it out, then cover the battery
For the operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-102)”.
• Place all control levers in NEUTRAL position, place the work equipment lock lever and parking brake lever
in LOCK position, and set the fuel control dial to Low idle (MIN) position.
• To prevent rust, fill the cooling circuit with Non-Amine Engine Coolant (AF-NAC) to give a density of at least
30% for the engine coolant.
MAINTENANCE DURING LONG-TERM STORAGE

k WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors
and windows to improve ventilation and prevent gas poisoning.
• During storage, operate and move the machine for a short distance once a month so that a new film of oil
will coat moving parts. At the same time, charge the battery as well.
• When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
• If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a
month to lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing
this. In addition, check the refrigerant level twice a year.
STARTING MACHINE AFTER LONG-TERM STORAGE

NOTICE
If the machine has been stored without performing the monthly rust-prevention operation, consult your
Komatsu distributor before using it.
When using the machine after long-term storage, perform the following items before using it.
• Wipe off the grease from the hydraulic cylinder rods.
• Add oil and grease at all lubrication points.
• When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before
and after starting the engine. If there is water in the oil, change all the oil.
• Insert the battery disconnect switch key and turn it to ON position.
For the operation method, see “BATTERY DISCONNECT SWITCH (3-102)”.
• If the machine is stored for a long period with the battery disconnect switch OFF or the battery terminal dis-
connected, the clock information and radio tuning information may be lost. In this case, set again. For de-
tail, see “CLOCK ADJUSTMENT (3-72)” and “HANDLING RADIO (3-216)”.
• When starting the engine, warm it up sufficiently according to the procedure in “METHOD FOR ENGINE
WARM-UP OPERATION (3-165)”.
3-232
OPERATION PRECAUTIONS FOR LONG-TERM STORAGE
If the machine has been stored for more than 2 months, perform the following procedure.
• Before starting the engine, replace DEF filter and fill up DEF tank according to the procedure in “METHOD
FOR REPLACING DEF FILTER (4-73)”.
• Start the engine and check correctly.
If SCR system has any abnormality, warning is displayed on the monitor screen and the audible alert
sounds. If SCR system has any abnormality, stop the engine, and then start it again.
If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor.
• If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement.
Dispose of drained DEF according to the local regulations and rules.
Aged DEF may have smell of ammonia. Replace DEF in a well-ventilated place and take care not to inhale
its vapor.
3-233
TROUBLES AND ACTIONS OPERATION
TROUBLES AND ACTIONS

ACTIONS WHEN RUNNING OUT OF FUEL
When starting the engine again after running out of fuel, fill with fuel until the fuel level caution lamp on the ma-
chine monitor goes out, then bleed the air from the fuel system before starting the engine.
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM

1. Insert the key into the starting switch and turn it to ON po-
sition (B).
The fuel feed pump is actuated.
2. Turn the starting switch to ON position (B), and keep it
there for 60 seconds (or 30 seconds when replacing the fil-
ter).
3. Return the starting switch to OFF position (A) and keep it

there for 10 seconds.
4. Repeat above steps 1. to 3. four times.
5. Turn the starting switch key to START position (C) and

start the engine.
Do not turn the starting motor continuously for more than
20 seconds. If the engine fails to start, wait for approxi-
mately 2 minutes, and then try to start the engine.
Do not repeat this operation more than 4 times.
6. If the engine does not starts, return the starting switch to
OFF position (A).
7. Approximately 10 minutes later (or approximately 15 mi-
nutes later when the ambient temperature is 5 °C or be-
low), repeat steps 1. to 5.
3-234
OPERATION TROUBLES AND ACTIONS
PRECAUTIONS FOR TOWING MACHINE

k WARNING
Always use the correct towing equipment and towing
method. Any mistake in the selection of the wire rope or
drawbar or the method of towing a disabled machine and
being towed may lead to serious personal injury or death.
• If the engine does not start, block the tracks from
movement, then release the brake. If blocks are not
used, there is a danger that the machine may move
suddenly.
• Always confirm that the wire rope or drawbar used for
towing has ample strength for the weight of the ma-
chine being towed.
• Never use the wire rope which has cut strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
• Always wear leather gloves when handling the wire
rope.
• Never tow a machine on a slope.
• During the towing operation, never stand between the
towing machine and the towed machine.
• Move the machine slowly.
Do not apply a sudden load to the wire rope.
NOTICE
The maximum towing capacity for this machine is 140000 N {14275 kg}.
Do not tow any load greater than this.
For details of the method of towing, contact your Komatsu distributor.
• If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic sys-
tem, the brake works and the machine cannot move. To move the machine in this case, the oil pressure in
the brake circuit must be heightened to the specified level with a special device. Contact your Komatsu dis-
tributor.
• Moving a machine by towing is only used to move it to a place where it is possible to perform inspection
and maintenance.
Do not tow it a long distance.
• If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on
the machine.
• Keep the angle of the towing line to the minimum. Operate the machine so that the angle does not become
greater than 30 ° from the straight travel direction.
• If the machine gets stuck in the mud or a heavy thing
needs to be towed, install a towing wire rope to the draw
bar pin.
Connect a wire rope to the part indicated with the arrow in
the drawing.
3-235
PRECAUTIONS FOR DISCHARGED BATTERY

k WARNING
• It is dangerous to charge a battery when installed on a
machine. Make sure that it is removed before charg-
ing.
• When checking or handling the battery, stop the en-
gine and turn the starting switch and battery discon-
nect switch keys to OFF positions.
• The battery generates hydrogen gas, and it is danger-
ous that it may explode. Do not bring open flame such
as lighted cigarettes near the battery, or do nothing
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, immediately wash it off with a large
amount of clean water.
If it gets in your eyes, wash the eyes immediately with
clean water, then consult a doctor for medical treat-
ment.
• When handling batteries, always wear protective eye-
glasses and rubber gloves.
• When removing the battery, first disconnect the cable
from the ground (normally the negative (-) terminal).
When installing, first connect the cable to the positive
(+) terminal.
If a tool touches the positive terminal and the chassis,
it is dangerous that it may cause a spark. Be extremely
careful.
• If the terminals are loose, it is dangerous that the de-
fective contact may generate sparks, and it may cause
an explosion.
Install the cable terminals securely.
• When removing or installing the cable terminals,
check which is the positive (+) terminal and which is
the negative (-) terminal.
METHOD FOR REMOVING AND INSTALLING BATTERY

1. Open the battery inspection cover.
3-236
2. Turn the battery disconnect switch to OFF position (O).

3. Loosen the terminal nut and disconnect the wiring from the
battery.
Before removing battery, remove the ground cable (nor-
mally connected to the negative (-) terminal).
If any tool touches the positive terminal of the battery and
the chassis, there is a danger that it will cause a spark.
4. Replace the battery.
5. After replacing the battery, fix the battery body with the bat-
tery mounting fixtures. (4 places)
Tightening torque
First nuts (A): 2.0 to 2.9 Nm {0.2 to 0.3 kgm}
Second nuts (B): 11.8 to 19.6 Nm {1.2 to 2.0 kgm}
6. Insert the terminal hole into the battery and tighten the nut.
When installing the battery, connect the ground cable last.
7. Turn the battery disconnect switch to ON position (I).
8. Close the battery inspection cover.
PRECAUTIONS FOR CHARGING BATTERY

k WARNING
When charging the battery, if the battery is not handled
correctly, it is dangerous that the battery may explode. Al-
ways follow the instruction manual accompanying the
charger, and observe the following.
• Set the voltage of the charger to match the voltage of
the battery to be charged. If the correct voltage is not
selected, the charger may overheat and cause an ex-
,&
plosion.
• Connect the positive (+) charger clip of the charger to
the positive (+) terminal of the battery, then connect
the negative (-) charger clip of the charger to the nega-
tive (-) terminal of the battery. Be sure to attach the
clips securely.
• Set the charging current to 1/10 of the value of the rat-
ed battery capacity; when performing rapid charging,
set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will
leak or the battery cells will dry up, and this may cause
the battery to catch fire and explode.
• If the battery electrolyte is frozen, do not charge the
battery or start the engine with a different power
source. It is dangerous that this may ignite the battery
electrolyte and cause the battery to explode.
• Do not use or charge the battery if the battery electro-
lyte level is below LOWER LEVEL line. This may cause
an explosion. Check the battery electrolyte level peri-
odically and add the purified water (such as a commer-
cial battery fluid) to bring the electrolyte level to UP-
PER LEVEL line.
3-237
START ENGINE WITH JUMPER CABLES

k WARNING
• When connecting the cables, never contact the posi-
tive (+) and negative (-) terminals.
• Always wear protective eyeglasses and rubber gloves
when starting the engine by using the jumper cable.
• Be careful not to let the normal machine and failed ma-
chine contact each other.
The sparks caused near the battery could ignite the
hydrogen gas generated from the battery, so be care-
ful not to let it happen.
• Make sure that there is no mistake in the jumper cable
connections. When the final cable is connected to the
engine block of the failed machine, sparks are generat-
ed. Accordingly, connect it to a point as far from the
battery as possible.
• When disconnecting the jumper cable, take care not to
bring the clips in contact with each other or with the
machine.
NOTICE
• The starting system for this machine uses 24 V. Accordingly, the normal machine must be equipped
with a 24 V battery.
• The sizes of the jumper cables and clips should be suitable for the battery size.
• The battery of the normal machine must be the same capacity as that of the failed machine.
• Check the cables and clips for damage or corrosion.
• Make sure that the cables and clips are firmly connected.
• Check that the work equipment lock levers and parking brake levers of both machines are in LOCK
position.
• Check that each lever is in NEUTRAL position.
• To prevent damage of the electric devices of the failed machine, turn the starting switch of the failed
machine to OFF position, check that the system operating lamp goes out, and then turn the battery
disconnect switch key to OFF position before connecting the jumper cables. For the operating
method of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-102)”.
PROCEDURE FOR CONNECTING JUMPER CABLE

Turn the starting switch and battery disconnect switch of the failed machine, and the starting switch of the nor-
mal machine to OFF position.
1. Connect the clip of jumper cable (A) to the positive (+) ter-
minal of battery (C) on the failed machine.
2. Connect the clip at the other end of jumper cable (A) to the
positive (+) terminal of battery (D) on the normal machine.
3. Connect the clip of jumper cable (B) to the negative (-) ter-
minal of battery (D) on the normal machine.
4. Turn the battery disconnect switch (S) of the failed ma-
chine to ON position.
5. Connect the clip at the other end of jumper cable (B) to en-
gine cylinder block (E) of the failed machine.
3-238
METHOD FOR STARTING ENGINE

1. Check both of normal machine and failed machine that the lock lever is set to LOCK position.
2. Check both of normal machine and failed machine that the control levers are in NEUTRAL position.
3. Make sure the clips are firmly connected to the battery terminals.
4. Start the engine of the normal machine and run it at high idle (Max. speed).
5. Turn the starting switch of the failed machine to START position and start the engine.
If the engine does not start at first, try again after 2 minutes or more.
PROCEDURE FOR REMOVING JUMPER CABLE

After the engine has started, disconnect the jumper cables in the reverse of the order in which they were con-
nected.
1. Remove the clip of jumper cable (B) from engine cylinder
block (E) on the failed machine.
2. Remove the clip of jumper cable (B) from the negative (-)
terminal of battery (D) on the normal machine.
3. Remove the clip of jumper cable (A) from the positive (+)
terminal of battery (D) on the normal machine.
4. Remove the clip of jumper cable (A) from the positive (+)
terminal of battery (C) on the failed machine.
OTHER TROUBLE
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM
• For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor.
• In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Problem Main causes Remedy
Lamp does not glow brightly even Defective wiring Check and repair loose terminal or
when the engine runs at high speeds. wire breakage. (*)
Defective belt Replace alternator belt. For details,
see WHEN REQUIRED. (*)
Lamp flickers while engine is running. Defective wiring Check and repair loose terminal or
wire breakage. (*)
Defective belt Replace alternator belt. For details,
see WHEN REQUIRED. (*)
Charge level caution lamp does not Defective alternator Replace. (*)
go out even when engine is running.
Defective wiring Check, repair. (*)
Alternator produces unusual noise. Defective alternator Replace. (*)
Starting motor does not rotate even Defective wiring Check, repair. (*)
when starting switch is turned to
Insufficient battery charge Charge battery.
START position.
Battery disconnect switch is at OFF Turn ON.
position.
Engine shutdown secondary switch at Set it to “NORMAL” position.
“STOP ENGINE” position
Defective adjustment of safety switch Adjust safety switch. (*)
Pinion of starting motor repeats en- Insufficient battery charge Charge battery.
gaging and disengaging (rattles).
3-239

Starting motor turns engine sluggish- Insufficient battery charge Charge battery.
ly.
Defective starting motor Replace. (*)
Starting motor disengages before en- Defective wiring Check, repair. (*)
gine starts.
Automatic preheating does not work. Defective wiring Check, repair. (*)
Defective heater relay Replace. (*)
Defective engine controller Check, replace (*)
Preheating pilot lamp does not light Defective wiring Check, repair. (*)
up.
Defective heater relay Replace. (*)
(when coolant temperature is -3 °C or
below) Defective monitor Replace. (*)
Oil pressure caution lamp does not Defective monitor Replace. (*)
light up when engine is stopped.
Defective caution lamp switch Replace. (*)
(starting switch is at ON position)
Charge level caution lamp does not Defective monitor Replace. (*)
light up when engine is stopped.
Defective wiring Check, repair. (*)
(starting switch is at ON position)
Outside of electrical intake air heater Defective wiring Check, repair. (*)
is not warm when touched with hand.
Wire breakage in electrical intake air Replace. (*)
heater
Defective operation of heater relay Check, repair heater relay. (*)
Defective operation of air conditioner Fuse blow Check, repair. (*)
Defective air conditioner switch Replace air conditioner switch. (*)
Defective blower switch Replace blower switch. (*)
Defective compressor Replace. (*)
Engine does not start. Damaged data in the controller Check, repair. (*)
(L04 lights up on monitor.) Other system troubles Check, repair. (*)
PHENOMENA AND ACTIONS FOR CHASSIS

When brake pedal is depressed, ma- Brakes out of adjustment, defective
Adjust, check, repair. (*)
chine does not stop. oil pressure
Track shoe comes off. Track tension is too low. Adjust track tension, see WHEN RE-
QUIRED.
Abnormal wear of sprocket Track shoe is too low, or too high. Adjust track tension, see WHEN RE-
QUIRED.
Blade and ripper rise slowly or do not Insufficient hydraulic oil level Set oil to specified level. See
rise. CHECKS BEFORE STARTING.
Work equipment lock lever is in Set to FREE.
LOCK.
3-240

When machine is steered, it does not Parking brake lever is in LOCK. Set to FREE.
turn.
Defective lever wiring Check, repair. (*)
Defective HSS pump Check, replace. (*)
Defective HSS motor Check, replace. (*)
Transmission oil pressure does not Gear pump is worn or scuffed. Check, replace. (*)
rise.
Power train case oil level is low. Set oil to specified level. See
CHECKS BEFORE STARTING.
Clogged oil filter element strainer of Clean. See EVERY 1000 HOURS
power train case MAINTENANCE.
Drawbar pull is low (travel speed is Insufficient engine horsepower See “PHENOMENA AND ACTIONS
low). FOR ENGINE RELATED PARTS”.
Travel speed increase is slow. Low power train oil temperature Warm-up engine.
Insufficient engine horsepower See “PHENOMENA AND ACTIONS
FOR ENGINE RELATED PARTS”.
When joystick (steering, directional Power train case oil level is low. Set oil to specified level. See
and gear shift lever) is operated, ma- CHECKS BEFORE STARTING.
chine does not start.
Transmission oil pressure does not See “Transmission oil pressure does
rise. not rise” shown above.
Parking brake lever is in LOCK. Set to FREE.
Machine does not travel straight. Defective adjustment of power train Adjust. (*)
controller
Defective steering valve Check, replace. (*)
Torque converter overheats (power Power train case oil level is low. Set oil to specified level. See
train oil temperature caution lamp CHECKS BEFORE STARTING.
lights up).
Transmission oil pressure does not See “Transmission oil pressure does
rise. not rise” shown above.
Work load is too high. Select speed range 1 range low, or
reduce load and increase speed dur-
ing work.
PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS

• As for the corrective actions indicated with (*) in the remedy column, always contact your Komatsu distribu-
tor.
After warming up, when engine Lowered oil level in engine oil pan Add oil to specified level. See
speed is increased, engine oil pres- (sucking in air) CHECK BEFORE STARTING.
sure caution lamp still lights up.
Improper oil is used. (Viscosity is im- Referring to “RECOMMENDED
proper.) FUEL, COOLANT, AND LUBRI-
CANT”, replace oil with proper one.
Clogged oil filter cartridge Replace. See EVERY 500 HOURS
MAINTENANCE.
Oil leakage due to defective tighten- Check, repair. (*)
ing or breakage of oil pipe or pipe
joint.
Defective monitor Replace. (*)
3-241

Steam spurts out from top of radiator. Lowered coolant level, leakage of Check, add coolant, repair. See
(pressure valve) coolant CHECK BEFORE STARTING.
Dirt or scale accumulated in cooling Change coolant, flush inside of cool-
system ing system. See WHEN REQUIRED.
Clogged radiator fins or damaged fin Clean or repair. See WHEN RE-
QUIRED.
Defective thermostat Replace thermostat. (*)
Loosened radiator filler cap (in high Tighten cap or replace packing.
altitude operation)
Defective monitor Replace monitor. (*)
Engine coolant temperature caution Lowered coolant level, leakage of Check, add coolant, repair. See
lamp lights up. coolant CHECK BEFORE STARTING.
Dirt or scale accumulated in cooling Change coolant, flush inside of cool-
system ing system. See WHEN REQUIRED.
Clogged radiator fins or damaged fin Clean or repair. See WHEN RE-
QUIRED.
Defective thermostat Replace thermostat. (*)
Loosened radiator filler cap (in high Tighten cap or replace packing.
altitude operation)
Defective monitor Replace monitor. (*)
Starting motor turns but engine does Lack of fuel Add oil to specified level. See
not start CHECK BEFORE STARTING.
Air in fuel system Repair portion where air is sucked in.
No fuel in fuel filter Fill fuel filter with fuel. See EVERY
500 HOURS MAINTENANCE. (*)
Starting motor incapable of cranking See “PHENOMENA AND ACTIONS
engine smoothly. FOR ELECTRICAL SYSTEM”.
Defective compression Adjust valve clearance. (*)
(Defective valve clearance)
Exhaust gas color is white or bluish. Excessive oil in oil pan Add oil to specified level. See
CHECK BEFORE STARTING.
Improper fuel Replace with specified fuel.
Water entry in KDPF Check and repair. (*)
Broken KDPF Replace KDPF. (*)
Exhaust gas sometimes becomes Broken KDPF Replace KDPF. (*)
black.
Combustion sound sometimes fluctu- Defective nozzle. Replace nozzle.
ates
Unusual noise is generated. Low grade fuel being used Replace with specified fuel.
(combustion or mechanical) Overheating Refer to “Engine coolant temperature
caution lamp lights up” shown above.
Broken inside of KDPF Replace KDPF. (*)
Excessive valve clearance Adjust valve clearance. (*)
3-242

DEF level caution lamp is displayed
Lowering of DEF level Add DEF.
on monitor.
Action level or caution lamp is dis-
Contact your Komatsu distributor.
played on monitor.
Alarm buzzer sounds. Contact your Komatsu distributor.
Engine suddenly lost power.
Contact your Komatsu distributor.
(Entered derate mode.)
IF MACHINE MONITOR SHOWS WARNING DISPLAY

When the action level display (1) or caution lamp (2) is shown
on the display of the machine monitor, press switch F5 to dis-
play the “Current Abnormality” screen and check the details
and remedy.
For the contents of the action level display and caution lamp,
see “WARNING DISPLAY (3-13)”.
Telephone number for the point of contact if an error occurs

When an error screen is displayed on the monitor, press the
switch F5 to display the “Current Abnormality” screen and tele-
phone number (3) for the point of contact is displayed in the
message column at the bottom of the screen.
REMARK
If no point of contact telephone number is registered, no tele-
phone number is displayed.
Ask your Komatsu distributor for the telephone number regis-
tration if necessary.
3-243
MAINTENANCE
4-1
PRECAUTIONS FOR MAINTENANCE MAINTENANCE
PRECAUTIONS FOR MAINTENANCE

Do not perform any inspection and maintenance operation that are not found in this manual.
CHECK SERVICE METER READING

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

Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts.
KOMATSU GENUINE LUBRICANTS

For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of
the specified viscosity according to the ambient temperature.
ALWAYS USE CLEAN WASHER FLUID

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

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away
from oil and grease.
CHECK DRAINED OIL AND USED FILTER

At the replacement of the filters when oil is changed, check the old oil and filters for metal particles and foreign
materials. If large quantity of metal particles or foreign materials are found, always report to the person in
charge, and perform suitable action.
PRECAUTIONS FOR REFILLING OIL OR FUEL

If your machine is equipped with a strainer, do not remove it while filling oil or fuel.
PRECAUTIONS FOR ADDING DEF

Do not remove the strainer while adding DEF.
It is recommended to use a nozzle having a diameter and a length specified by ISO 22241-4 and an auto stop
function to add DEF.
WELDING INSTRUCTIONS
• When performing welding, turn the starting switch to OFF position, check that the system operating lamp is
not lit. Turn the battery disconnect switch to OFF position, and remove the key.
• Do not apply a voltage higher than 200 V continuously.
• Connect grounding cable within 1 m of the area to be welded. If grounding cable is connected near instru-
ments, connectors, etc., the instruments may malfunction.
• Prevent seals, bearings or bushings from entering the space between the weld zone and grounding point.
Seals and the like can cause damage to the nearby parts by catching fire from sparks.
• Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
Sparks generated there can damage the plated portion.
DO NOT DROP THINGS INSIDE MACHINE

• When opening the inspection windows or the oil filler port of the tank to perform inspection, be careful not to
drop nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine,
and will lead to failure. If anything drops, be sure to take it out.
• Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
4-2
MAINTENANCE PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR KDPF

When performing inspection and maintenance during or just after regeneration, take care of the high tempera-
ture parts.
Even after the engine stops the parts around KDPF may be at high temperature.
PRECAUTIONS FOR SCR ASSEMBLY

Be careful for the high temperature parts when performing inspection and maintenance. Even after the engine
stops the parts around SCR device may be at high temperature.
DUSTY JOBSITES
When working at dusty jobsites, observe the following.
• Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not
to let the fins become clogged.
• Replace the fuel filter more frequently.
• Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
• When checking and replacing the oil or filters, move the machine to a place where there is no dust and take
care to prevent dust from entering the system.
AVOID MIXING OIL

Never mix different brand or grade of oil. If a different brand or grade of oil has to be added, drain the old oil and
replace all the oil with the new brand or grade of oil.
LOCK INSPECTION COVERS

Lock inspection cover securely into position with the lock bar, etc. If inspection or maintenance is performed with
inspection cover not locked in position, there is a danger that it may be suddenly shut by the wind and cause
personal injury.
PRECAUTIONS FOR OPENING AND CLOSING ENGINE SIDE COVER

• When standing on track to open the engine side cover,
adopt a standing position, hold the side cover with both
thumbs, and open it slowly with your other fingers.
• Fully close or open the engine side cover until it is locked
and then open or close the cab door.
BLEED AIR FROM HYDRAULIC CIRCUIT

When hydraulic equipment is repaired or replaced, or the hydraulic piping is disconnected, the air must be bled
from the circuit. For bleeding air, see “METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT (4-35)”.
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES

• When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace them with new parts.
When doing this, be careful not to forget to assemble O-rings and gaskets.
• When installing the hoses, do not twist them or bend them sharply.
If they are installed so, their service life will be extremely shortened and they may be damaged.
CHECKS AFTER INSPECTION AND MAINTENANCE

If you forget to perform the inspection and maintenance, unexpected problems may occur, and this may lead to
personal injury. Always observe the following.
4-3
PRECAUTIONS FOR MAINTENANCE MAINTENANCE
Checks after operation (with engine stopped)

• Have any inspection and maintenance points been forgotten?
• Have all inspection and maintenance items been performed correctly?
• Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
• Are there any leakage of coolant or oil? Have all nuts and bolts been tightened?
Checks while the engine is running
For details of the checks when the engine is running, see SAFETY, “TWO WORKERS FOR MAINTENANCE
WHEN ENGINE IS RUNNING (2-27)” and pay attention to safety.
• Increase the engine speed to check for the leakage of fuel or oil.
• Check if the inspected and serviced area is normally operated.
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE

It is necessary to select fuel or lubricant according to the ambient temperature.
For detail, see “RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-6)”.
4-4
MAINTENANCE OUTLINE OF MAINTENANCE
OUTLINE OF MAINTENANCE
• Komatsu recommends using Komatsu genuine parts for replacement parts, grease or oil.
• When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all
the old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no prob-
lem if the small amount of oil remaining in the piping mixes with the new oil.)
• Unless otherwise specified, when the machine is shipped from the plant, it is filled with the oil and coolant
listed in the table below.
Item Type
Engine oil pan Engine oil EO15W40–LA (Komatsu genuine)
Power train case
Final drive case
Power train oil TO30 (Komatsu genuine)
Damper case
Idler
Hydraulic tank Power train oil TO10 (Komatsu genuine)
Non-Amine Engine Coolant (AF-NAC) (Komatsu genuine) (density: 30% or
Radiator
above)
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

OIL
• Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature,
high pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in
Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil at the specified interval.
• Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of failures with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
• Never mix oils of different grades or brands.
• Always add the specified amount of oil.
Having too much oil or too little oil are both causes of failures.
• If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such
cases, consult your Komatsu distributor.
• When changing the oil, always replace the related filters at the same time.
• We recommend that you have an oil analysis periodically to check the condition of the machine. For those
who wish to use this service, consult your Komatsu distributor.
• When shipped from the plant, power train oil TO10 is used.
When using HO46-HM hydraulic oil, replace the specified amount (all capacity).
Use of hydraulic oil out of our recommendation can cause clogging of the filter. Accordingly, do not use it.
Oil remaining in the piping and cylinders may be mixed in.
NOTICE
Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu
genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the en-
gine such as deteriorated oil may reduce lubricating function, and it may cause failure, shortening of
the machine life, lowering of performance and increase of fuel consumption.
FUEL
• To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel
tank with fuel after completing the day's work.
4-5
OUTLINE OF MAINTENANCE MAINTENANCE
• The fuel pump is a precision equipment, and if fuel containing water or dirt is used, it cannot work properly.
• Be extremely careful not to let impurities get in when storing or adding fuel.
• Always use the fuel specified for the temperature that is described in Operation and Maintenance Manual.
• If the fuel is used at the temperatures lower than the specified temperature (particularly at tempera-
tures below -15 °C), the fuel will solidify.
• If the fuel is used at temperatures higher than the specified temperature, the viscosity will drop, and it
may result in troubles such as a drop of output.
• Before starting the engine, or after 10 minutes of adding fuel, drain the sediment and water from the fuel
tank.
• If the engine runs out of fuel, or if the filters are replaced, it is necessary to bleed the air from the circuit.
• If there is any foreign material in the fuel tank, wash the tank and fuel system.
NOTICE
The fuel used must be ultra low-sulfur diesel fuel. (≤10 ppm)
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted
on this machine uses an electronically controlled high-pressure fuel injection device and emission gas
control system (KDPF). Since the high-pressure fuel injection device requires high precision parts and
lubrication, if low viscosity fuel with low lubricating ability is used, its durability may drop considerably.
And using fuel with high sulfur content can deteriorate the engine parts and KDPF catalyzer, inducing
failures, decrease of the life and degradation in performance.
COOLANT AND WATER FOR DILUTION

• The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of coolant is essential.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant
(AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for
2 years or 4000 hours.
Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may
cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
• When using antifreeze, always observe the precautions given in Operation and Maintenance Manual.
• Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable.
• The coolant density needs to be changed according to the ambient temperature.
For details of the coolant density, see “METHOD FOR CLEANING INSIDE OF COOLING SYSTEM
(4-19)”.
Even in areas where it is not considered necessary to prevent freezing, always use Non-Amine Engine
Coolant (AF-NAC) with a density of over 30 % in order to prevent corrosion of the cooling system.
Non-Amine Engine Coolant (AF-NAC) is diluted with distilled water that does not contain any ions or water-
hardening substances. Never dilute with water.
• If the engine overheats, wait for the engine to cool before adding coolant.
• If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air
entering the coolant.
DEF
• If DEF gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes
off and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated
or begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.
4-6
• When opening the cap of DEF tank of the machine, the ammonia vapour may escape. Keep your face
away from the filler port.
• Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause
a fire. Some fluids or agents added can create and emit a toxic gas.
• DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas.
• If DEF is spilled, immediately wash and clean the area with water. If spilled DEF is left unattended and the
area is not washed and cleaned, it can cause corrosion to the contaminated area and emit toxic gas.
• When disposing of DEF, treat it as an industrial waste. The container for DEF is an industrial waste as well.
It should be treated in the same way.
• Never use an iron or aluminum container when disposing DEF, because toxic gas may develop and a
chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel
when handling the fluid waste of DEF.
NOTICE
If you add any additional additive agents or water to DEF, the devices in the Urea SCR system may be
defective, and conformance to the exhaust gas regulations will be lost.
GREASE
• Grease is used to prevent seizure and noises at the joints.
• This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom-
mended grease and follow the replacement intervals and recommended ambient temperatures given in this
Operation and Maintenance Manual.
• Grease fittings not included in the periodic maintenance section are the grease fittings for overhaul, so they
do not need grease.
If any part becomes stiff after being used for long time, add grease.
• Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would
cause wear of the rotating parts.
PERFORM KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA,
the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and
other problems.
Thanks to long term experience and ample data accumulated, we can grasp condition of your machine accu-
rately and provide proper recommendation.
We strongly recommend you to use this service. The oil analysis is performed at actual cost, so the cost is low,
and results of the analysis and recommendations are reported promptly.
KOWA analysis items
Measurement of metallic powder concentration
An ICP (Inductively Coupled Plasma) analyzer is used for
measuring the concentration of iron, copper, and other metal
powder in the oil.
4-7
Measurement of quantity of iron particles

A PQI (Particle Quantifier Index) measuring instrument is used
for measuring the quantity of iron particles of 5 μm or more, en-
abling early detection of failures.
Others
Measurements are made of items such as the ratio of water, coolant, and fuel in the oil, and dynamic viscosity, if
necessary, to enable a highly precise diagnosis of the machine and the components' condition.
Oil sampling interval
500 hours
Precautions when sampling
• Make sure that the oil is well mixed before sampling.
• Perform sampling at regular fixed intervals.
• Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, contact your Komatsu distributor.
STORE OIL AND FUEL

• Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
• When keeping drum cans for a long period, lay the drums so that the filler ports of the drums are located in
the lower part of the side to prevent moisture from being sucked in. If drums have to be stored outside, cov-
er them with a waterproof sheet or take other measures to protect them.
• To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out
(use the oldest oil or fuel first).
STORE DEF
• Completely seal up its container for storage. Only open containers in a well-ventilated area.
• When storing DEF, avoid direct sunlight. Always use the original container. Make sure that transfer equip-
ment and tank must meet DEF compatible material specification. If DEF is stored in an iron or aluminum
container, toxic gas may develop and a chemical reaction may corrode the container.
• The relationship between the upper limit of storage temperature and the storage period of DEF is shown in
the table.
Temperature of storage area Storage period
Max.10 °C Up to 36 months
*: Do not store DEF in the temperature of 35 °C or above.

For the storage in cold weather, see the section about DEF in “COLD WEATHER OPERATION (3-229)”.
FILTER
• Filters are extremely important safety parts. They prevent impurities in the oil, fuel, and air circuits from en-
tering important equipment and causing problems. Replace all filters periodically. For details, see Operation
and Maintenance Manual.
4-8
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and
fuel (sulphur content) being used.
• Never try to clean and use again the filters (cartridge type). Always replace them with new filters.
• When replacing oil filters, check if any metal particles are attached to the old filters.
If any metal particles are found, consult your Komatsu distributor.
• Do not open packages of spare filters until just before they are to be used.
• Komatsu recommends using Komatsu genuine filters.
HANDLE ELECTRICAL COMPONENTS

k WARNING
• When the battery disconnect switch key is turned to OFF position for the maintenance work, always
pull out the key and keep it with you. If the key is left in the switch, someone may turn ON the power
by mistake. It is dangerous that causes an electric shock.
For the operation of the battery disconnect switch, see “BATTERY DISCONNECT SWITCH (3-102)”.
• It is extremely dangerous if the electrical component becomes wet or the covering of the wiring is
damaged. This will cause an electrical leakage and may lead to malfunction of the machine. Do not
wash the inside of the operator's cab with water. When washing the machine, be careful not to let
water get into the electrical components.
• When removing the connectors of electrical components after washing the machine or in the rain, wipe off
the water drop stuck around connectors before removing the connectors and keep the water drop away
from inside of the connectors.
• Checking and maintenance items are checking fan belt tension, checking damage of the fan belt and
checking battery fluid level.
• Komatsu recommends installing electric components specified by Komatsu.
• External electro-magnetic interference may cause malfunction of the control system controller. Accordingly,
consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma-
chine.
• When working at the seashore, keep the electrical component clean to prevent corrosion.
• When installing electrical component, connect it to the special power supply connector.
Do not connect the optional power supply to the fuse or starting switch or battery relay, etc.
HANDLE HYDRAULIC COMPONENTS

• The hydraulic system is at high temperature during and just after operation. In addition, high pressure is
applied to the hydraulic system, thus pay attention to the following matters when performing inspection and
maintenance of it.
• Lower the work equipment to the ground on a level place, and work so that no pressure is applied to
the cylinder circuits.
• Be sure to stop the engine.
• Since the hydraulic oil and lubricating oil are at high temperature and high pressure just after operation,
wait until the oil temperature at each part decreases, and then start maintenance.
Internal pressure may be high even after the temperature decreases.
When loosening a plug, screw, or hose, avoid standing in front of them and loosen gradually and re-
lease the internal pressure, and then remove.
• When performing inspection and maintenance of the hydraulic circuit, be sure to release air from the
hydraulic tank to release the internal pressure.
• The inspection and maintenance include check of the hydraulic oil level, replacement of filters, replacement
of the hydraulic oil.
• When the high-pressure hoses, etc. are disconnected, check the O-rings for damage. If they are damaged,
replace them.
4-9
• When the hydraulic oil filter element or strainer is replaced or cleaned, or when a hydraulic component is
repaired, replaced, or its piping is removed, air in the circuit must be bled.
• The accumulator is charged with high-pressure nitrogen gas, and it is extremely dangerous if it is handled
incorrectly.
4-10
MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
STANDARD TIGHTENING TORQUE FOR BOLTS AND

NUTS
Tightening torque list
k CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage
to the tightened parts, and this will cause failure of the machine or problems with operation. Always be
careful when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to

the torque shown in the table below.
If it is necessary to replace any nut or bolt, Komatsu recom-
mends using Komatsu genuine part of the same size as the
part that is removed.
Thread Width Tightening torque

diameter across
Target value Allowable range
of bolt flats (b)
(a) (mm) (mm) Nm kgm Nm kgm
6 10 13.2 1.35 11.8 - 14.7 1.2 - 1.5
8 13 31 3.2 27 - 34 2.8 - 3.5
10 17 66 6.7 59 - 74 6.0 - 7.5
12 19 113 11.5 98 - 123 10.0 - 12.5
14 22 172 17.5 153 - 190 15.5 - 19.5
16 24 260 26.5 235 - 285 23.5 - 29.5
18 27 360 37.0 320 - 400 33.0 - 41.0
20 30 510 52.3 455 - 565 46.5 - 58.0
22 32 688 70.3 610 - 765 62.5 - 78.0
24 36 883 90.0 785 - 980 80.0 - 100.0
27 41 1,295 132.5 1,150 - 1,440 118.0 - 147.0
30 46 1,720 175.0 1,520 - 1,910 155.0 - 195.0
33 50 2,210 225.0 1,960 - 2,450 200.0 - 250.0
36 55 2,750 280.0 2,450 - 3,040 250.0 - 310.0
39 60 3,280 335.0 2,890 - 3,630 295.0 - 370.0
Apply the following table for hydraulic hose.
4-11
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE
Width Tightening torque

Nominal - No. of across
Target value Allowable range
threads "a" flats "b"
(mm) Nm kgm Nm kgm
9/16-18UNF 19 44 4.5 35 to 54 3.5 to 5.5
11/16-16UN 22 74 7.5 54 to 93 5.5 to 9.5
13/16-16UN 27 103 10.5 84 to 132 8.5 to 13.5
1-14UNS 32 157 16.0 128 to 186 13.0 to 19.0
1 3/16-12UN 36 216 22.0 177 to 245 18.0 to 25.0
4-12
MAINTENANCE MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
If the currently used diesel fuel which does not include the bio-fuel is changed to the one mixed with the bio-fuel,
the replacement interval of the fuel filter is changed as well. See “MAINTENANCE INTERVAL WHEN DIESEL
FUEL MIXED WITH BIO-FUEL IS USED”.
MAINTENANCE SCHEDULE TABLE
WHEN REQUIRED ........................................................................................................................................ 4-15
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER .......................................... 4-15
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM ................................................................. 4-19
METHOD FOR CHECKING AND ADJUSTING TRACK TENSION ......................................................... 4-21
METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE BOLTS .......................... 4-22
METHOD FOR CHECKING IDLER OIL LEVEL ...................................................................................... 4-23
METHOD FOR ADJUSTING IDLER CLEARANCE ................................................................................. 4-24
METHOD FOR LUBRICATING UNIVERSAL JOINT ............................................................................... 4-25
METHOD FOR INVERTING AND REPLACING CUTTING EDGE AND END BIT ................................... 4-25
CLEAN AND CHECK RADIATOR FINS AND OIL COOLER FINS .......................................................... 4-27
METHOD FOR CLEANING HYDRAULIC TANK BREATHER ................................................................. 4-29
METHOD FOR CLEANING FUEL TANK BREATHER............................................................................. 4-30
METHOD FOR CHECKING AND ADJUSTING ALTERNATOR AND AIR CONDITIONER COMPRESSOR
BELT TENSION................................................................................................................................... 4-30
METHOD FOR REPLACING DOOR DAMPER....................................................................................... 4-31
METHOD FOR LUBRICATING DOOR HINGE........................................................................................ 4-31
METHOD FOR CHECKING DOOR LATCH ............................................................................................ 4-31
METHOD FOR CHECKING DOOR LOCK STRIKER.............................................................................. 4-31
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID ................................. 4-32
METHOD FOR REPLACING WIPER BLADE ......................................................................................... 4-32
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER................................................. 4-33
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT .............................................................. 4-35
METHOD FOR LUBRICATING ............................................................................................................... 4-35
METHOD FOR INSTALLING TRUNNION CAP....................................................................................... 4-35
ADJUST SHIMS, ADJUST TENSION AT WORK EQUIPMENT LINKS ................................................... 4-36
CHECKS BEFORE STARTING...................................................................................................................... 4-41
EVERY 50 HOURS MAINTENANCE ............................................................................................................. 4-41
METHOD FOR LUBRICATING POWER ANGLE POWER TILT DOZER ................................................ 4-41
EVERY 250 HOURS MAINTENANCE ........................................................................................................... 4-42
METHOD FOR LUBRICATING ............................................................................................................... 4-42
METHOD FOR LUBRICATING EQUALIZER BAR SIDE PIN .................................................................. 4-44
METHOD FOR LUBRICATING EQUALIZER BAR CENTER PIN............................................................ 4-44
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL ..................................... 4-45
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL ............................................................. 4-45
METHOD FOR CHECKING AND CLEANING ADDITIONAL FUEL STRAINER...................................... 4-48
METHOD FOR CHECKING BRAKE PERFORMANCE........................................................................... 4-48
EVERY 500 HOURS MAINTENANCE ........................................................................................................... 4-49
METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE .....
............................................................................................................................................................ 4-49
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................... 4-51
METHOD FOR REPLACING ELEMENT ON POWER TRAIN OIL FILTER ............................................. 4-53
METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC FILTERS ....................................... 4-54
EVERY 1000 HOURS MAINTENANCE ......................................................................................................... 4-55
METHOD FOR CHANGING OIL IN POWER TRAIN CASE, CLEAN POWER TRAIN PUMP STRAINER
AND SCAVENGING PUMP STRAINER .............................................................................................. 4-55
METHOD FOR CHANGING OIL IN FINAL DRIVE CASE ....................................................................... 4-57
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE ............................................................ 4-58
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT......................................................... 4-60
METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS.............. 4-61
METHOD FOR CLEANING POWER TRAIN CASE BREATHER ............................................................ 4-61
METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ............................................. 4-62
METHOD FOR REPLACING DEF TANK BREATHER ELEMENT........................................................... 4-62
4-13
MAINTENANCE SCHEDULE MAINTENANCE
METHOD FOR CHECKING OIL LEVEL IN DAMPER CASE AND ADDING OIL..................................... 4-63
METHOD FOR CHECKING FOR LOOSE ROPS MOUNT BOLTS ......................................................... 4-64
METHOD FOR CHANGING OIL IN DAMPER CASE .............................................................................. 4-64
METHOD FOR CHANGING OIL IN HYDRAULIC TANK, REPLACING HYDRAULIC OIL FILTER ELEMENT,
AND CLEANING HYDRAULIC TANK STRAINER ............................................................................... 4-65
METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA-
TOR (FOR CONTROL CIRCUIT) ........................................................................................................ 4-67
METHOD FOR CHECKING ALTERNATOR ............................................................................................ 4-70
METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE ...................................... 4-70
METHOD FOR REPLACING KCCV FILTER ELEMENT ......................................................................... 4-70
METHOD FOR REPLACING DEF FILTER.............................................................................................. 4-73
REPLACE DEFINED LIFE PARTS.......................................................................................................... 4-75
METHOD FOR CHECKING WATER PUMP............................................................................................ 4-76
METHOD FOR CHECKING STARTING MOTOR.................................................................................... 4-76
METHOD FOR REPLACING ACCUMULATOR (FOR CONTROL CIRCUIT) .......................................... 4-76
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH-PRESSURE PIPING CLAMP, HARD-
ENING OF RUBBER ........................................................................................................................... 4-77
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.
............................................................................................................................................................ 4-78
METHOD FOR CLEANING KDPF .......................................................................................................... 4-79
METHOD FOR CLEANING DEF TANK................................................................................................... 4-79
METHOD FOR CLEANING DEF TANK MOUNTING PORTION ............................................................. 4-79
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP............................................................ 4-79
METHOD FOR REPLACING DEF HOSE ............................................................................................... 4-80
END OF SERVICE LIFE ......................................................................................................................... 4-80
4-14
MAINTENANCE MAINTENANCE PROCEDURE
MAINTENANCE PROCEDURE
WHEN REQUIRED
METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER
k WARNING
• If inspection, cleaning, or maintenance is performed while the engine is running, dust enters into
the engine and damages it. Be sure to stop the engine before performing these works.
• When using compressed air, there is a danger that dirt may scatter and cause personal injury. Al-
ways wear protective equipment such as protective eyeglasses and dust mask.
• When working in high places or where the foothold is poor, be careful not to fall because of the re-
action when pulling out the element.
METHOD OF CHECKING
NOTICE
Do not clean the element before the air cleaner clogging caution lamp lights up or the yellow piston of
the dust indicator laps over the peripheral red zone.
If the element is cleaned before the above, the air cleaner cannot display its normal performance and
the cleaning effect decreases.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner ele-
ment.
In the following cases, clean or replace the air cleaner element.
• When the air cleaner clogging caution lamp lights up
4-15
MAINTENANCE PROCEDURE MAINTENANCE
• When the inside yellow piston of dust indicator (1) laps

over the peripheral red zone (A)
METHOD FOR CLEANING AND REPLACING OUTER ELEMENT

2. Remove clips (2) (3 pieces) and remove cover (3).
NOTICE
• After the outer element has been cleaned 6 times, or if
the air cleaner element has been used for 1 year, re-
place the outer element, inner element, and O-ring.
• Before and after cleaning the element, do not leave or
keep it under direct sunlight.
• Never remove inner element (5). If it is removed, dirt
will enter and can cause an engine trouble.
• Do not use a screwdriver or other tool.
3. When removing outer element (4), hold it and pull it out
while gently moving it up and down, right and left.
4. Cover the air connector at the bottom of the air cleaner body with a clean cloth or tapes to prevent entry of
dirt.
5. Clean the interior of the air cleaner body, cover (3) and vacuator valve (6) with a clean cloth, a whisk or
others.
4-16
6. Blow dry compressed air (Max. 0.2 MPa {2.1 kg/cm2}) from
the inside of the outer element along the pleats.
7. Blow dry compressed air from the outside of the outer ele-
ment along the pleats.
8. Blow dry compressed air again from the inside of the outer
element along the pleats.
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.
When cleaning the element, do not hit it or beat it against
something.
Do not use the element with damaged pleats or a damaged
gasket or seal.
9. Remove the cloths and tapes installed in step 4.
10. Check the seal of the cleaned or new element for adhesion
of dusts and oil.
Wipe off all of sticking oil, etc., if any.
NOTICE
• Do not clean and reuse the inner element. When replacing the outer element, replace the inner
element with new one at the same time.
• If the outer element and cover are installed while the inner element is not installed properly, the
outer element may be damaged.
• The sealing portion of the improper part lacks precision, and allows the entry of dust, which
leads to damage of the engine. Do not use such improper part.
11. Check that the inner element is fitted securely.
If the inner element is not fitted securely, push it in properly.
12. Install the cleaned outer element.
NOTICE
When installing cover (3), check O-ring (7) for a
scratch, etc. If it has any scratch, etc., replace it with a
new one.
13. Set the arrow mark on cover (3) at the top, install to the air
cleaner body, then secure with clip (2).
14. Push the button of dust indicator (1).

15. Close the engine side cover on the left side of the ma-
chine.
4-17
If the air cleaner clogging caution lamp lights up soon after cleaning or the yellow piston of dust indicator (1)
laps over the red zone (7.5 kPa {0.08 kg/cm2}), even if the outer element has not been cleaned up to 6 times,
replace both the inner and outer elements.
METHOD FOR REPLACING ELEMENT

1. Open the engine side cover on the left side of the ma-
chine.
2. Remove clips (2) (3 pieces) and remove cover (3).
3. Hold the outer element (4), rock it lightly up and down and
to the right and left, and pull the element out.
Do not remove inner element (5) at this time.
4. Clean the interior of the air cleaner body, cover (3) and va-
cuator valve (6) with a clean cloth, a whisk or others.
NOTICE
• If the outer element and cover are installed while
the inner element is not installed properly, the out-
er element may be damaged.
When installation is correct, protrusion (a) of the
inner element from the air cleaner body is 35 mm.
• Do not clean and reuse the inner element. When
replacing the outer element, replace the inner ele-
ment with new one at the same time.
• The sealing portion of the improper part lacks pre-
cision, and allows the entry of dust, which leads to
damage of the engine. Do not use such improper
part.
5. Remove inner element (5), then quickly install the new inner element.
Install the inner element securely so that it does not move.
6. Install new outer element (4).
7. Replace O-ring (7) of cover (3) with a new one.
8. Set the arrow mark on cover (3) at the top, install to the air
cleaner body, then secure with clip (2).
4-18
9. Push the button of dust indicator (1).

REMARK
Immediately after a new element has been installed, the
yellow piston of the dust indicator may go to the 2nd posi-
tion, but this does not indicate any abnormality.
10. Close the engine side cover on the left side of the ma-
chine.
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM

k WARNING
• Immediately after the engine is stopped, the coolant is still hot and the pressure is accumulated in
the radiator. If the cap is removed under this condition and the coolant is drained, it may cause
burns. Always wait for the temperature to go down, turn the cap slowly to release the pressure.
• Start the engine and clean it. When standing up or leaving the operator's seat, lock the parking
brake lever and work equipment lock lever.
• For starting the engine, see “CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE (3-132)” and
“METHOD FOR STARTING ENGINE (3-159)”.
• Never approach the fan at the front of the machine while the engine is running. There is a danger of
touching the fan.
• It is very dangerous to go under the machine for cleaning while the engine is running, since the ma-
chine may move unexpectedly. While the engine is running, never go under the machine.
Place the machine on a level ground when cleaning or changing the coolant.
Clean the inside of the cooling system, change the coolant according to the following table.
Cleaning of inside of cooling system and re-
Coolant
placement of coolant
Non-Amine Engine Coolant Every 2 years or 4000 hours, whichever
(AF-NAC) comes sooner
The coolant has the important function of preventing corrosion as well as preventing freezing.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-
NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years
or 4000 hours.
cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
To maintain the anti-corrosion properties of Non-Amine Engine Coolant (AF-NAC), always keep the density of
Non-Amine Engine Coolant between 30 % and 64 %.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water. When using coolant, investigate the
lowest temperature in the past and decide the density for the coolant from the following coolant density table.
When deciding the density for the coolant, set it for a temperature 10 °C below the actual lowest temperature in
the working area.
The coolant density varies according to the ambient temperature, but it must be over 30 % at least.
Coolant density table

Min. atmospheric tem-
°C Min. -10 -15 -20 -25 -30 -35 -40 -45 -50
perature
4-19
Density (%) 30 36 41 46 50 54 58 61 64
k WARNING
• Coolant is toxic. When opening the drain valve, be careful not to get coolant on you. If it gets in
your eyes, flush your eyes with large amount of fresh water and see a doctor immediately.
• When handling the cooling water containing coolant that has been drained during changing the
coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to
perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the
ground surface.
Non-Amine Engine Coolant (AF-NAC) is already diluted with distilled water, so it is not flammable. (For dilution
water, see “COOLANT AND WATER FOR DILUTION (4-6)”.)
Check the density with a coolant tester.
Prepare a hose to use when filling with coolant and water.
Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant.
1. Place the machine on a level place.
2. Stop the engine.
3. Turn radiator cap (1) slowly until it hits the stopper and re-
lease the pressure.
4. While pushing radiator cap (1), turn it until it touches to the
stopper, then remove it.
5. Put containers to catch the coolant under drain valve (2) at
the bottom of the radiator and under drain valve (3) at the
side of the cylinder block.
6. Open drain valves (2) and (3) to drain the coolant.
7. After draining the coolant, close drain valve (2) and drain
valve(3) and fill with city water.
8. After the radiator is filled with water, start the engine.
9. Run the engine at low idle for approximately 10 minutes.
10. Stop the engine.
11. Open drain valves (2) and (3) to drain the water.
12. Close drain valves (2) and (3).
13. Add Non-Amine Engine Coolant (AF-NAC) through the
coolant filler port up to the mouth of the port.
For the density of Non-Amine Engine Coolant (AF-NAC) ,
see “Coolant density table”.
15. Run the engine at low idle for 5 minutes, and then run at
full speed for a further 5 minutes. (At this time, keep the ra-
diator cap removed.)
The air is bled from the coolant.
16. Drain the coolant in reservoir tank (4).
17. Clean the inside of reservoir tank (4).
4-20
18. Add Non-Amine Engine Coolant (AF-NAC) to the middle

between FULL and LOW.
19. Stop the engine.
20. After 3 minutes, add Non-Amine Engine Coolant (AF-NAC)
up to the mouth of the coolant filler port.
21. Tighten radiator cap (1).
22. Check the coolant level in reservoir tank (4).
If necessary, add Non-Amine Engine Coolant (AF-NAC).
METHOD FOR CHECKING AND ADJUSTING TRACK TENSION

The wear of the pins and bushings of the undercarriage depends on the working condition and soil conditions.
Check the track tension occasionally and keep it at the standard level.
Perform check and adjustment on a level and firm ground.
METHOD OF CHECKING
1. Drive the machine forward on a flat place, and stop without
applying the brake.
2. Place a straight bar between the carrier roller and idler as
shown in the figure.
When clearance (a) between the bar and grouser is 20 to
30 mm at the center, the tension is in the standard range.
If the track tension is not in the standard range, adjust it.
METHOD FOR ADJUSTING

k WARNING
Never loosen plug (1) more than 1 turn.
If plug (1) is loosened more than 1 turn, there is a danger
of plug (1) flying out under the high internal pressure of
the grease.
Never loosen any part other than plug (1). Never put your
face in the mounting direction of plug (1).
If the track tension cannot be loosened by the above pro-
cedure, ask your Komatsu distributor for repair.
METHOD FOR INCREASING TRACK TENSION

NOTICE
• The safety indicator is stuck to the back of cover (3). Take care not to damage the safety indicator.
• When removing cover (3), be careful not to let any dirt or soil get in.
Prepare a grease pump.
4-21

2. Pump in grease through grease fitting (2) by using a
grease pump.
Grease can be pumped in until dimension (S) becomes

zero (0). If the track tension is still loose, the pins and
bushings are excessively worn. The pins and bushings
need to be turned 180 deg. or replaced. Ask your Komatsu
distributor for repair.
3. Move the machine backward and forward.
4. Check the belt tension again.
Check that the track tension is proper.
If the track tension is not proper, adjust it again.
METHOD FOR DECREASING TRACK TENSION

k WARNING
It is extremely dangerous to release the grease by any method other than the following procedure.
If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs.
NOTICE
• The safety indicator is stuck to the back of cover (3). Take care not to damage the safety indicator.
• When removing cover (3), be careful not to let any dirt or soil get in.
2. Loosen plug (1) gradually to release the grease.
When loosening plug (1), turn it a maximum of 1 turn.
If the grease does not come out smoothly, move the ma-
chine forward and backward a short distance.
3. Tighten plug (1).
4. Move the machine backward and forward.
5. Check the belt tension again.
Check that the track tension is proper.
If the track tension is not proper, adjust it again.
METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE

BOLTS
NOTICE
If the machine is used with track shoe bolts loose, they will break. Tighten any loose bolt immediately.
4-22
1. Check for looseness of track shoe bolt (1).

2. If any bolt is loose, retighten it.
METHOD FOR RETIGHTENING TRACK SHOE BOLT

1. Tighten the track shoe bolts in the order shown in the fig-
ure.
Tightening torque of shoe bolt: 539 ± 49 Nm {55 ± 5 kgm}
2. Check that the nut and track shoe are in close contact with
the link contact surface.
3. After checking, retighten by 120 ± 10 °.
METHOD FOR RETIGHTENING MASTER LINK CONNECTING BOLT

1. Tighten the master link connecting bolts in the order shown
in the figure.
Tightening torque for master link connecting bolt: 343
± 39 Nm {35 ± 4 kgm}
2. Check that the link contact surfaces are fitted.
3. After checking, tighten by 180 ° (Allowable range: 0 ° to
20 °).
METHOD FOR CHECKING IDLER OIL LEVEL

k WARNING
When the oil level is low and new oil must be added, the machine body needs to be inclined, and that is
dangerous.
Ask your Komatsu distributor for addition.
Low oil level in the idler can cause noise and seizure. Stop the machine on a flat place and check for the oil
level according to the following procedure.
4-23
1. Remove bolts (1).

2. Remove guide plate (2) and shim (3).
Keep removed shim (3) in a safe place and be careful not
to lose it.
3. Loosen plug (4) gradually and check that oil oozes out
through the thread portion.
• When oil oozes out through thread portion
You do not need to add oil.
• When no oil oozes out through thread portion
The oil is insufficient. Ask your Komatsu distributor for
adding.
4. After checking, tighten plug (4).
5. Install guide plate (2) and shim (3).
6. Install bolts (1).
REMARK
When installing guide plate (2), install the same number and thickness of shims as removed shims (3).
The optimum condition may be obtained, if the clearance of the idler is adjusted at the same time. For the ad-
justment method, see “METHOD FOR ADJUSTING IDLER CLEARANCE”.
METHOD FOR ADJUSTING IDLER CLEARANCE

Since the idlers are forced to move forward and backward by an external force, guide plates will be worn out.
Wear of guide plates will cause the vibration of idlers from side to side or inclination of the idlers, and running off
of track links from the idlers or unevenly worn idler and links may result.
Adjust as follows.
1. Drive the machine by 1 to 2 m on a flat place.
2. Measure clearance (A) between track frame (1) and guide
plate (2) (4 places on the right and left, and inside and out-
side).
• When clearance (A) is less than 4 mm .
The clearance of the idler does not need to be adjus-
ted.
• When clearance (A) is 4 mm or more
Adjust the clearance of the idler.
1) Loosen bolt (3).
2) Remove some shims and adjust the clearance on
each side to 0.5 to 1 mm.
Thickness of 1 shim is 1 mm.
4-24
METHOD FOR LUBRICATING UNIVERSAL JOINT

k WARNING
The undercover is a heavy part (22 kg). Do not open or close the cover just under it.
When removing bolts(2), perform the work from the rear of the cover so that you can easily get out of
the way.
1. Remove the undercover on the lower rear side of the ma-

chine.
1) Remove bolts (1) (2 pieces) on the front side of the
machine.
2) While supporting the cover, gradually remove bolts (2)
(2 pieces) on the rear side of the machine.
3) Lower and open the cover gradually.

(A) Front of machine
(B) Dangerous place
2. Supply grease to the grease fitting shown by arrow. (2 pla-

ces)
METHOD FOR INVERTING AND REPLACING CUTTING EDGE AND END BIT
k WARNING
It is dangerous if the work equipment moves by mistake when the cutting edge and end bit are turned
180 ° or replaced.
Set the work equipment in a stable condition, place the work equipment lock lever in LOCK position,
then stop the engine.
Turn the cutting edges and end bits 180 ° or replace them before they are worn out to the blade end.
1. Raise the blade to proper height, and place blocks under it to prevent it from lowering.
2. Set the work equipment lock lever to LOCK position.
3. Stop the engine.
4-25
4. Judge the wear of the end bit and cutting edge by the following wear standards.
Wear standards
Item Criteria ( mm)
Work Standard
Repair
No. Measuring point equip- dimen-
limit
ment sion
A, C 242 187
Height of end bit (out-
a B, F, G 204 187
side)
D, E 225 198
A, C 330 300
b Width of end bit B, F, G 325 300
D, E 511 440
A, B, C,
204 187
c Height of end bit (inside) F, G
D, E 205 198
Height of cutting edge
A, B, C,
d (Center of bolt mounting D, E, F, G 102 85
hole to edge)
The symbols of the work equipment are as follows;

A: Straight tilt dozer (D65EX)
B: Straight tilt dozer (D65PX)
C: Angle dozer (D65EX)
D: Sigma dozer (D65EX)
E: Sigma dozer (D65WX)
F: Power angle power tilt dozer (D65EX)
G: Power angle power tilt dozer (D65WX, D65PX)
REMARK
If both sides of the cutting edge are worn out, replace with new ones.
5. Loosen nut (1) and remove bolt (2).
6. Remove the cutting edge and end bit.
7. Clean the mounting face.
8. Turn the cutting edge and end bit 180 degrees or replace
them with new ones.
9. Install the cutting edge and end bit, and tighten them light-
ly.
If nut (1) and bolt (2) are damaged, replace them as well.
10. Press the blade against the ground to eliminate of the play
of bolt (2).
11. Tighten the bolt to the specified torque.
Tightening torque of mounting nut:
• Straight tilt dozer: 392 to 530 Nm {40 to 54 kgm}
• Angle dozer: 392 to 530 Nm {40 to 54 kgm}
• SIGMA dozer: 392 to 530 Nm {40 to 54 kgm}
• Power angle power tilt dozer: 392 to 530 Nm {40 to 54 kgm}
4-26
12. After operating several hours, retighten the mounting nut.
CLEAN AND CHECK RADIATOR FINS AND OIL COOLER FINS

If there is any mud or dirt stuck to the radiator or oil cooler, clean them.
Check the rubber hoses. If they are cracked or fragile, replace them. Also, check the hose clamp for looseness.
METHOD FOR CLEANING FIN BY ROTATING HYDRAULIC DRIVE FAN IN RE-

VERSE
NOTICE
When the hydraulic drive fan rotates in reverse, take extreme care of scattering of dust.
When stopping the engine during the Fan Reverse Mode, first run the engine at low idle, then stop it.
The dust and dirt stuck to the radiator and cooler can be blown out by rotating the hydraulic fan in the reverse
direction.
1. Turn starting switch (1) to OFF position and stop the en-
gine.
2. Fully open engine side covers (2) on the right and left of
the machine and lock them.
3. Turn starting switch (1) to ON position.
4-27
4. On the user menu, set Fan Reverse Mode.

For setting of Fan Reverse Mode, see “REVERSE HY-
DRAULIC FAN (3-63)”.
REMARK
Even if Fan Reverse Mode is set while the engine is run-
ning, the fan rotation direction is not reversed.
The screen in the figure is displayed to inform the operator
that the direction of rotation of the fan has not been
changed.
Stop the engine once and follow the steps 2. and 3.
5. Turn the starting switch (1) to START position and start the
engine.
The hydraulic fan rotates in reverse.
6. Turn the fuel control dial at High idle (MAX) position, and run the engine at high idle.
Change the time for running the engine at high idle corresponding to seriousness of clogging.
Normal clogging: 1 to 2 minutes
Excessive clogging: 2 to 3 minutes
7. After cleaning, turn the fuel control dial to Low idle (MIN) position.
Run the engine at low idle for approximately 10 seconds.
8. Turn starting switch (1) to OFF position and stop the engine.
9. Close engine side cover (2) on the right and left side of the machine.
REMARK
• If dirt is caught in the radiator fins, blow with compressed air to clean.
• In a cold circumstance, perform the cleaning by Fan Reverse Mode within less than 5 minutes.
If the fan reverse rotation is performed for a long time, DEF hose may freeze.
CLEAN WITH COMPRESSED AIR

k WARNING
• If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the
compressed air, high-pressure water, or steam, there is a danger of personal injury. Always wear
protective equipment such as protective eyeglasses and dust mask.
• When performing cleaning, always stop the engine and check that the fan is not rotating. If you
touch the fan when it is rotating, it will cause serious personal injury or death.
4-28
METHOD FOR CLEANING RADIATOR FIN AND AFTERCOOLER FIN

1. Remove bolts (1) (8 pieces) of the radiator grille.
2. Open radiator grille (2).
3. Blow off mud, dirt, leaves, etc. in the radiator fins with com-
pressed air.
You may use steam or water instead of compressed air.
4. Check the rubber hoses.
If they are cracked or fragile, replace them.
5. Check the hose clamps for looseness.
METHOD FOR CLEANING OIL COOLER FIN AND AIR CONDITIONER CONDENS-
ER NET
1. Open the engine side cover on the right and left sides of the machine.
2. Use compressed air to remove the mud, dirt, and leaves
clogging hydraulic oil cooler fins (1) and air conditioner
condenser net (2).
You may use steam or water instead of compressed air.
3. Check the rubber hoses.
If they are cracked or fragile, replace them.
4. Check the hose clamps for looseness.
5. Clean the space between the front surface of the hydraulic

oil cooler and the rear surface of the radiator.
1) Remove mounting bolt (4).
2) Remove cover (3).
3) Use compressed air to blow off the mud, dirt, or
leaves clogging the space.
METHOD FOR CLEANING HYDRAULIC TANK BREATHER

At the check and maintenance, if the breather is dirty, clean it.
4-29
1. Remove nut (2) of breather assembly (1) on the top of the

hydraulic tank.
3. Remove dirt sticking to breather element (4).
4. Clean in clean diesel fuel or flushing oil.
5. Install cover (3) and nut (2).
Tightening torque: 10 to 14 Nm {1.0 to 1.4 kgm}
METHOD FOR CLEANING FUEL TANK BREATHER

At the check and maintenance, if the breather is dirty, clean it.
fuel tank.
3. Remove dirt sticking to breather element (4).
4. Clean in clean diesel fuel or flushing oil.
METHOD FOR CHECKING AND ADJUSTING ALTERNATOR AND AIR CONDI-

TIONER COMPRESSOR BELT TENSION
For replacement of the alternator and air conditioner compressor drive belt, ask your Komatsu distributor.
4-30
METHOD FOR REPLACING DOOR DAMPER

Measure groove depth (A) of door damper rubber (1).
When groove depth (A) decreases to 2 mm or less, replace the
damper.
The damper is installed at top and bottom, 2 pieces each on
the R.H. and L.H. doors.
METHOD FOR LUBRICATING DOOR HINGE

Perform this when the door creaks when it opens or closes.
1. Supply spray lubricant through the bushing slit of the
hinge.
2. If the bushing is worn, replace the hinge.
METHOD FOR CHECKING DOOR LATCH

1. Keep the door open.
2. Check if the grease in the latch dried out.
If the amount of grease is low or there is no more grease,
coat the inside of the latch with grease from portion (1).
REMARK
If there is no more grease inside the latch, the movement of the door will become poor because of dust inside
the latch, and the handle may become heavy when you open the door.
METHOD FOR CHECKING DOOR LOCK STRIKER

Measure wear (A) of the door lock striker.
If wear (A) is 0.5 mm or more, replace the door lock striker.
If you use it as it is, its play increases and can cause breakage
of the hinge and lock door.
4-31
METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID

Perform this check when no window washer fluid comes out.
1. Open the battery inspection cover at the rear of the machine.
2. Check the fluid level in window washer tank (1).
If the fluid level is low, remove cap (2) and add window
washer fluid for automobile through the filler port.
Be careful not to let dirt or dust get in when adding fluid.
(Mixture ratio of pure washer fluid and water)

The proper mixing proportion varies with the ambient temperature. Add washer fluid diluted with water at the
following proportion.
Area, season Mixing proportion Freezing temperature
Normal Washer fluid 1/3: water 2/3 -10 °C
Winter in cold district Washer fluid 1/2: water 1/2 -20 °C
Winter in extremely cold district Pure washer fluid -30 °C
There are 2 types depending on the freezing temperature: -10 °C (general use) and -30 °C (cold district use),
select according to the area and season.
METHOD FOR REPLACING WIPER BLADE

If the blade is damaged, it will not wipe the window clean, so
replace the blade.
METHOD FOR REPLACING FRONT WIPER

The front wiper is hooked at portion (A).
4-32
1. Move the blade in the direction of the arrow.

The blade comes off.
2. Install the new blade and hook it securely.
METHOD FOR REPLACING REAR WIPER

1. Remove E-ring (1).
2. Fit a new blade, then install it securely with E-ring (1).
METHOD FOR REPLACING DOOR WIPER

The front wiper is hooked at portion (A).
1. Move the blade in the direction of the arrow.
2. Install the new blade and hook it securely.
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER

METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR DRIVE BELT TEN-
SION
If the driving belt slackens, it is likely to slip, lowering the cooling efficiency.
The air conditioner compressor drive belt is on the left side of
the machine.
4-33
1. Loosen compressor bracket mounting bolts (1) (4 pieces)

and adjustment bolt (2), and move compressor (3).
2. Tighten adjustment bolt (2) and compressor bracket
mounting bolts (1) (4 pieces) and tense the air conditioner
compressor drive belt.
When adjusting the air conditioner compressor drive belt,
do not push the compressor directly with a bar, etc., but
use adjustment bolt (2).
3. Press the center between drive pulley (4) and compressor

pulley (5) with a finger.
Pressing force: Approx. 98 N {10 kg}
4. Adjust the tension so that deflection (A) is 12 to 15 mm.
When the belt is new, it elongates particularly. After 2 to 3
days, be sure to adjust again.
METHOD FOR CHECKING LEVEL OF REFRIGERANT (GAS)

k WARNING
• Be sure to handle the refrigerant (gas) according to the local regulations.
• If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss
of sight or frostbite. Never touch the refrigerant. Do not loosen any part of the refrigerant circuit.
• Do not bring open flame close to a refrigerant leaking point.
If the level of the refrigerant (gas) is low, the cooling effect will be reduced. Perform the check while running the
engine at high idle and operating the air conditioner at high speed.
Check the condition of the refrigerant gas (Hydrofluorocarbons
HFC -134a) that circulates the refrigerant circuit, through sight
glass (2) (inspection window) of receiver (1).
(A) No bubbles in refrigerant flow: Suitable

(B) Some bubbles in refrigerant flow (bubbles pass continuous-
ly): Insufficient
(C) Colorless, transparent: No refrigerant
4-34
REMARK
If bubbles are seen, the gas is insufficient. Ask your Komatsu distributor for adding.
If the air conditioner is operated with the refrigerant gas level low, it will cause damage to the compressor.
Hydrofluorocarbons HFC -134a is used as the refrigerant.
METHOD FOR CHECKING DURING OFF SEASON

Even during the off-season, operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at
all parts of the compressor.
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT

Since the engine must be started and the blade must be operated, see OPERATION.
For the starting procedure of the engine, see “METHOD FOR STARTING ENGINE (3-159)”.
NOTICE
If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end,
air taken inside the cylinder may cause damage to the piston packing.
2. Run the engine at low idle.
3. Move each cylinder of the work equipment to approximately 100 mm before the stroke end, and repeat ex-
tension and retraction for 5 minutes.
Take care not to move the cylinder to the stroke end.
4. Next, operate each cylinder 3 to 4 more times to each stroke end.
5. Finally, operate each cylinder 4 to 5 times to the end of its stroke to completely remove the air.
METHOD FOR LUBRICATING

2. Stop the engine.
3. Remove the cover under the monitor and control panel.
4. By using a grease pump, pump in grease through the
grease fittings.
(1) Brake pedal
(2) Decelerator pedal
(3) Brake rod
5. After greasing, wipe off any old grease that is pushed out.
METHOD FOR INSTALLING TRUNNION CAP

2. Set the work equipment lock lever to LOCK position.
3. Stop the engine.
4. Install the shims. (Top, bottom: 2 places)
(A) Standard number of shims: Thickness 1 mm x 10
pieces
5. Tighten bolts (1) alternately until they reach the specified
torque.
For detail, see “METHOD FOR ADJUSTING SHIMS AT
TRUNNION (4-39)”.
Thread diameter of clamp-
Tightening torque
ing bolt Shim part No. Specifications of work equipment
( Nm { kgm)
( mm )
4-35
Straight tilt dozer

Straight tilt power pitch dozer
785 to 980
24 14Y-71-22280 Sigma dozer
{80 to 100}
Sigma power pitch dozer
Angle dozer
1150 to 1440
27 14X-72-51460 Power angle power tilt dozer
{118 to 147}
ADJUST SHIMS, ADJUST TENSION AT WORK EQUIPMENT LINKS

When assembling the work equipment, perform adjustment as follows.
Check the play of the links periodically and perform adjustment.
When disassembling the machine for transportation, be careful not to lose the shims.
NEED FOR ADJUSTING WORK EQUIPMENT LINKS

k CAUTION
If the clearances at each ball joint of the work equipment and the tension of the center brace are not
adjusted properly, it will lead to problems.
It is necessary to perform adjustment properly regardless of whether the machine is new and regardless
of the number of years that it has been used.
Problems that occur when adjustment is not correct

Location Status Problems that appear
Work equipment play becomes excessive and performance deteriorates
Ball joint portion Excessive play Sand or dust enters through gap and causes wear
(Portion A in the fig- Impact load at joints increases and durability is reduced
ure)
Ball cannot rotate, excessive bending stress is generated, and cracks or
No play
damage occur
Work equipment play becomes excessive and performance deteriorates
Insufficient ten- Sand or dust enters bushing at blade connection and causes wear
Center brace sion
(Portion B in the fig- Shaking to side increases, lift cylinder hose contacts exterior parts and
ure) frame contacts track
Excessive ten-
Excessive bending tension is generated, and cracks or damage occur
sion
(Straight tilt dozer)

(Straight tilt power pitch dozer)
(SIGMADOZER)
(Sigma power pitch dozer)
4-36
(Angle dozer)
There is no portion B on the angle dozer.
METHOD FOR ADJUSTING LOCATIONS AND METHOD FOR ADJUSTING WORK

EQUIPMENT LINKS
k WARNING
It is dangerous if the work equipment moves by mistake when it is being adjusted.
Park the machine on a level ground, set the work equipment in a stable state, and stop the engine. Se-
curely set the parking brake lever and work equipment lock lever in LOCK position.
1. Adjust the play of each link ball joint at positions (1) to (4).
(1) Tilt brace, tilt cylinder head, pitch cylinder head
(2) Lift cylinder head
(3) Center brace
(4) Trunnion
2. Adjust the tension of center brace (5).
(SIGMADOZER)
(Angle dozer)
REMARK
For the adjustment method of each portion, see “METHOD FOR ADJUSTING SHIMS AT TILT BRACE, TILT
CYLINDER HEAD, AND PITCH CYLINDER HEAD (4-38)”, “METHOD FOR ADJUSTING SHIMS AT LIFT
CYLINDER HEAD (4-38)”, “METHOD FOR ADJUSTING SHIMS AT CENTER BRACE (4-39)”, “METHOD
FOR ADJUSTING SHIMS AT TRUNNION (4-39)”, or “METHOD FOR ADJUSTING TENSION OF CENTER
BRACE (4-40)”.
4-37
METHOD FOR ADJUSTING SHIMS AT TILT BRACE, TILT CYLINDER HEAD, AND
PITCH CYLINDER HEAD
• Correct value for play at ball joint: 0.2 to 0.7 mm
• Standard shim thickness: 5 mm
Adjust the play in the ball joint to the correct value, according to the following procedure.
1. Remove bolts (1), and remove cap (2).
2. Wipe off the grease and dirt from the sliding surface of ball
(3).
3. Remove all shims (4).
4. Install cap (2) and tighten bolts (1) lightly.
Tightening torque: 19.6 to 29.4 Nm {2 to 3 kgm}
5. Measure clearance at portion A (top) and portion B (bot-
tom) of ball joint, and calculate average clearance C[C =
(A+B)/2].
6. Set so that the shim thickness is between (C + 0.2) to (C
+ 0.7) mm.
The shim thickness can be set in units of 0.5 mm.
8. Install shims of the thickness set in step 6 to the top and bottom.
9. Tighten cap (2) with bolts (1).
10. Operate the work equipment and check that there is no abnormal noise or abnormal play.
11. Pump in grease through the grease fitting of the ball joint.
12. Wipe off any old grease that is pushed out.
METHOD FOR ADJUSTING SHIMS AT LIFT CYLINDER HEAD

(3).
(A+B)/2].
+ 0.7) mm .
4-38
METHOD FOR ADJUSTING SHIMS AT CENTER BRACE

(3).
tom) of ball joint, and calculate average clearance C [C =
(A+B)/2].
+ 0.7) mm.
METHOD FOR ADJUSTING SHIMS AT TRUNNION

4-39

(3).
Tightening torque: 39.2 to 49 Nm {4 to 5 kgm}
(A+B)/2].
+ 1.2) mm.
The shim thickness can be set in units of 1 mm.
8. Install shims of the thickness set in step 6 to the top and
bottom.
Tighten bolts (1) in turn at the top and bottom to reach the
specified torque.
Tightening torque Specifications of work
( Nm{ kgm}) equipment
Straight tilt dozer

Straight tilt power pitch doz-
785 to 980 er
{80 to 100} Sigma dozer
Sigma power pitch dozer
Angle dozer
1150 to 1440 Power angle power tilt doz-
{118 to 147} er
METHOD FOR ADJUSTING TENSION OF CENTER BRACE

(Sigma dozer)
When transporting the machine, remove the whole set of the work equipment. When installing again, adjust the
tension of the center brace.
If the adjustment is not performed, the bushing at the mounting portion of the blade and straight frame comes
off, and soil and sand enter and cause premature wear or damage of the bushing. Adjust as follows.
k WARNING
Except when operating the blade in step 4, always lock the blade control lever securely with the work
equipment lock lever.
4-40
1. Adjust with shim (2) so that the play of ball joint (1) is 0.2
to 0.7 mm.
For the adjustment method, see “METHOD FOR ADJUST-
ING SHIMS AT CENTER BRACE (4-39)”.
2. Loosen bolt (3).
3. Install the work equipment assembly.
4. Operate the blade control lever to float the blade.
5. Insert the bar in center brace hole (4) and turn the bar to
the protruding side.
Adjust clearance between the track shoe and frame (A) so
that it is equal on the right and left sides.
Rotating torque: 24.5 to 49 Nm {2.5 to 5 kgm} (Blade at FLOAT)
Standard distance between the joints (B) is as shown below.
(D65EX)
Straight tilt dozer, straight tilt power pitch dozer: 995 mm
Sigma dozer, sigma power pitch dozer: 991 mm
(D65PX)
Straight tilt dozer, straight tilt power pitch dozer: 992 mm
(D65WX)
Sigma dozer, sigma power pitch dozer: 992 mm
6. Tighten bolt (3).
Tightening torque: 490.3 to 608 Nm {50 to 62 kgm}
CHECKS BEFORE STARTING

For the following items, see OPERATION, “METHOD FOR CHECKING BEFORE STARTING (3-133)”.
• Method for draining water and sediment from fuel tank
• Method for checking water separator, draining water and sediment
• Method for checking oil level in hydraulic tank, adding oil
• Method for checking coolant level, adding coolant
• Method for checking oil level in engine oil pan, adding oil
• Method for checking oil level in power train case and adding oil
• Method for checking dust indicator
• Method for checking brake pedal travel
• Method for checking electric wiring
• Method for checking fuel level, adding fuel
• Method for checking DEF level, adding DEF
• Method for checking lamps operation
• Method for checking machine monitor
• Method for removing deposit in engine compartment
• Method for checking horn operation
• Method for checking backup alarm operation status
EVERY 50 HOURS MAINTENANCE

METHOD FOR LUBRICATING POWER ANGLE POWER TILT DOZER
1. Lower the blade to the ground and stop the engine.
2. By using a grease pump, pump in grease through the grease fittings.
4-41
Greasing point
(1) Pitch rod pin (2 places) (3) Center ball (1 place)

(2) Turnbuckle screw (2 places) (4) U-frame trunnion (2 places)

Maintenance for every 50 hours service should be performed at the same time.
METHOD FOR LUBRICATING

1. Lower the blade to the ground and stop the engine.
When lubricating the lift cylinder support shaft, lower the blade to raise the idler 1 to 2 cm from the ground,
then stop the engine.
2. By using a grease pump, pump in grease through the grease fittings.
Greasing points of straight tilt dozer and sigma dozer
(1) Lift cylinder support yoke (4 places)
(2) Lift cylinder support shaft (2 places)
4-42
(3) Lift cylinder ball joint (2 places)

(4) Tilt cylinder ball joint (1 place)
(5) Tilt brace ball joint (1 places)
(6) Brace ball joint (2 places)
(7) Tilt brace thread portion (1 place) (screw-adjustable)
Lubrication points of straight tilt power pitch dozer and sigma power pitch dozer

(4) Tilt cylinder ball joint (1 place)
(5) Pitch cylinder ball joint (1 place)
(6) Brace ball joint (2 places)
Lubricating points of angle dozer


(4) Tilt brace ball joint (1 places)
(5) Tilt brace thread (2 places)
4-43
Lubricating points of power angle power tilt dozer

(3) Lift cylinder head pin (2 places)

(4) Angle cylinder bottom pin (2 place)
(5) Angle cylinder head pin (2 places)
(6) Tilt cylinder bottom pin (1 place)
(7) Tilt cylinder head pin (1 place)
METHOD FOR LUBRICATING EQUALIZER BAR SIDE PIN

(1 place each on right and left sides)
1. Remove all soil and sand from the top of the track frame
and top of the cover.
2. Clean the grease fitting shown by arrow.
3. Supply grease by using a grease pump.
REMARK
• Supply 3 shots of grease (Operate the grease pump
lever 3 times) to each grease fitting, and check that
grease is newly discharged through the seal lip.
• If grease is not newly discharged through the lip por-
tion, continue supplying grease until it is discharged.
• If the blade is lowered to raise the idler 1 to 2 cm from
the ground in order when performing lubrication, the
grease will fill the whole circumference of the pin.
METHOD FOR LUBRICATING EQUALIZER BAR CENTER PIN

(1 place)
4-44
2. Clean the grease fitting shown by arrow.

3. Supply grease by using a grease pump.
REMARK
If the blade is lowered to raise the idler 1 to 2 cm from the
ground in order when performing lubrication, the grease
will fill the whole circumference of the pin.
METHOD FOR CHECKING OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL
k WARNING
Immediately after the engine is stopped, parts and oil are still very hot. Accordingly, wait until they have
cooled down before starting the work.
1. Stop the machine so that drain plug (1) is directly at the

bottom.
2. Remove oil level plug (2) and check the oil level.
• When the oil level is near the lower edge of the plug
hole
Install oil level plug (2).
• When the oil level is far below the lower edge of the
plug hole
The oil is insufficient. Add oil.
1) Remove oil filler plug (3).
2) Add oil until it flows out of the hole of oil level plug (2).
3) Install oil filler plug (3) and oil level plug (2).
METHOD FOR CHECKING BATTERY ELECTROLYTE LEVEL

k WARNING
• Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. If you do so, it will
reduce the service life of the battery. In addition, it may cause an explosion.
• Since the battery produces combustible gas, it can explode. Do not bring any open flame close.
• Battery electrolyte is dangerous object. Also, take care that it does not stick your eye or skin. If bat-
tery electrolyte sticks to your skin, wash it away with large amounts of water, then get medical at-
tention.
• Do not add the electrolyte to the battery exceeding UPPER LEVEL line. It may leak and cause dam-
age to the paint surface or corrode other parts.
• Do not use a dry wipe to clean the battery. A wet wipe will prevent fire or explosion from static elec-
tricity.
NOTICE
If there is a fear that the battery water may freeze after refilling with purified water (such as a commer-
cial battery fluid), do the replenishment before the day's work on the next day.
Perform this procedure before operating the machine.
Inspect the battery electrolyte level at least once a month.
4-45
METHOD FOR CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY

If it is possible to check the electrolyte level from the side of the battery, check as follows.
1. Open the battery inspection cover at the rear left of the machine.
2. Clean around the electrolyte level line with a cloth wet with water.
3. Check the electrolyte level.
• When the electrolyte level is between UPPER LEVEL
(U.L.) line and LOWER LEVEL (L.L.) line.
The battery electrolyte level is proper.
• When the electrolyte level is below the center line be-
tween UPPER LEVEL (U.L.) line and LOWER LEVEL
(L.L.) line.
The battery electrolyte level is low. Add purified water
according to the following procedure.
1) Remove the vinyl sheet (1) installed above the battery.
2) Remove cap (2) immediately and add purified water

(example: commercially available battery liquid) up to
UPPER LEVEL (U.L.) line.
3) After adding the purified water, tighten cap (2) secure-
ly.
REMARK
If purified water is added to above U.L. line, use a syringe to lower the level to U.L. line. Neutralize the removed
fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, con-
sult your Komatsu distributor or a battery manufacturer.
METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO

CHECK FROM SIDE OF BATTERY
If it is impossible to check the electrolyte level from the side of the battery, or there is no UPPER LEVEL line on
the side of the battery, check as follows.
1. Open the battery inspection cover at the rear left of the machine.
4-46
2. Remove the vinyl sheet (1) installed above the battery.
3. Remove caps (2) from the top of the battery.

4. Look into fluid filler port (3) and check the electrolyte level.
(A) Correct level: Electrolyte level is up to bottom of
sleeve, so surface tension causes electrolyte surface to
bulge and pole plate appears to be warped.
(B) Low: Electrolyte level is not up to bottom of sleeve, so
poles appear straight and not bent.
If the electrolyte does not reach sleeve (4), always add the
purified water (such as a commercial battery fluid) so that
the level reaches the bottom of sleeve (4) (UPPER LEV-
EL).
5. After checking adding the purified water, tighten cap (2)
securely.
REMARK
If the purified water is added to above the bottom of sleeve (4), use a syringe to remove electrolyte to the bot-
tom of sleeve (4). Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a
large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer.
METHOD FOR CHECKING ELECTROLYTE LEVEL ON INDICATOR ETC

If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
4-47
METHOD FOR CHECKING AND CLEANING ADDITIONAL FUEL STRAINER

1. Open cover (1).
2. Turn fuel supply valve (2) to CLOSE position (C).
3. Remove strainer cap (3).
The strainer forms one unit with strainer cap (3).
4. Remove all dirt from the strainer, then wash it in clean die-
sel fuel or flushing oil.
If the strainer is damaged, replace it.
5. Install the strainer.
6. Tighten strainer cap (3).
Replace the O-ring at the same time.
7. Turn fuel supply valve (2) to OPEN position (O).
METHOD FOR CHECKING BRAKE PERFORMANCE

k WARNING
If the machine moves off during the following operation, ask your Komatsu distributor for repairs imme-
diately.
NOTICE
Never set the joystick (steering, directional and gear shift lever) to the 1st gear speed. This will cause
damage to the machine.
Before starting the engine, check the safety around the machine, and then perform the following operation.
1. Turn the starting switch key to START position (C).
The engine starts.
4-48
2. After the warm-up operation, turn fuel control dial (1) to

Low idle (MIN) position .
3. Set work equipment lock lever (2) to FREE position (F).
4. Operate blade control lever (3) to float the blade.
Leave work equipment lock lever (2) in FREE position (F).
5. Set parking brake lever (4) to FREE position (F).
6. Depress brake pedal (5) and set joystick (steering, direc-
tional and gear shift lever) (6) to FORWARD position.
7. Press the upshift button to set the transmission into 2nd
gear speed.
8. Operate fuel control dial (1) and gradually raise the engine
speed to full throttle.
Keep depressing brake pedal (5).
9. Check if the machine moves.
• When the machine does not move
The brake is normal.
• When the machine moves
Immediately ask your Komatsu distributor for repair.

Maintenance for every 50 and 250 hours should be performed at the same time.
METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL
FILTER CARTRIDGE
k WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Refill capacity: 30.5 ℓ

Prepare a socket wrench and a filter wrench.
1. Remove cover (1) under the machine and put a container
just under the drain plug to receive the oil.
4-49
2. Take the end of hose (2) out of the inspection window.

3. Loosen drain plug (P) to drain oil. Do it slowly so that you
do not get splashed with drained oil.
4. Check the drained oil.
If there are excessive metal particles or foreign material,
contact your Komatsu distributor.
5. Tighten drain plug (P).
6. Open the engine side cover on the right side of the ma-
chine.
7. Remove bolts (3) (2 pieces) and remove underside cover
(4).
8. Turn engine oil filter cartridge (5) counterclockwise by us-

ing the filter wrench, and remove it.
9. Clean the filter head.
10. Fill the new filter cartridge with clean oil, coat the packing
face and thread with oil (or coat thinly with grease), then
install the filter cartridge.
11. After the packing surface reaches the filter head, tighten
the filter cartridge 3/4 to 1 turn.
12. After replacing the filter cartridge, refill with engine oil
through oil filler port (F) until the oil level is between H and
L marks on dipstick (G).
13. Run the engine at low idle for a while and then stop it.
14. Check that the oil level is between H and L marks on the
dipstick.
15. For the checking method, see “METHOD FOR CHECKING
OIL LEVEL IN ENGINE OIL PAN, ADDING OIL (3-136)”.
4-50
REMARK
When the ambient temperature is low, water or emulsified matter may stick to the dipstick, oil filler cap, etc. or
the drained oil may be milky white because of water vapor in the blowby gas. However, if the coolant level is
normal, it is not a problem.
There is no problem even if the emulsified matter cannot be removed completely after changing oil.
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE

k WARNING
• Just after the engine stops, all parts are still very hot, so do not replace the filter immediately. Wait
until all of parts cool down before starting the work.
• High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.
• Do not bring any open flame close.
NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing parts, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu-
ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Never use a substitute.
• When performing the inspection or maintenance of the fuel system, pay more attention than normal
to the entry of dirt. If dirt sticks to any part, use fuel to wash it off completely.
Prepare a filter wrench and a container to catch the oil.
1. Open the inspection cover at the bottom of the fuel tank.
2. Turn fuel supply valve (1) at the bottom of the fuel tank to
CLOSE position (C).
3. Open the battery inspection cover at the rear left of the
machine.
4-51
4. Place the oil container under filter cartridge (2).

5. Remove connector (3) of the water separator sensor and
remove the sensor harness from clip (4).
After removing the connector, cover it with a vinyl bag to
prevent water from getting on it.
6. Remove hose (5).
7. Turn transparent cup (6) counterclockwise by using the fil-
ter wrench and remove it.
This cap is used again. If the cap is damaged, replace it
with a new one.
8. Turn filter cartridge (2) counterclockwise by using the filter
wrench, and remove it.
9. Install currently removed transparent cup (6) to the bottom
of the new filter cartridge.
At this time, be sure replace O-ring (7) with a new one.
When the O-ring has been replaced, coat the surface with
clean fuel before installing it.
10. After the packing surface touches the seal surface of the
filter cartridge, tighten transparent cup (6) 1/4 to 1/2 turn.
Tightening torque of transparent cup: 10 Nm {1.0 kgm}
REMARK
If the transparent cup is fastened too much, the O-ring will be damaged and this leads to leakage of fuel. If
it is too loose, fuel will also leak from gaps of the O-ring. Therefore, be sure to observe the tightening angle.
12. Fill the new filter cartridge with clean fuel, thinly apply oil to the packing surface, then install it to the filter
head.
NOTICE
• When filling the filter cartridge with fuel, do not re-
move cap (B). Always fill with fuel from small
holes (A) (8 places) on the dirty side.
• After filling with fuel, remove cap (B) and install
the fuel filter.
• Always fill with clean fuel. Be careful not to let any
dirt or dust get into the fuel. In particular, center
portion is the clean side, so do not remove cap (B)
when filling with fuel. Be careful not to let dirt or
dust get into the center portion on the clean side.
13. After the packing surface reaches the sealing surface of the filter head, tighten the filter cartridge 3/4 turns.
REMARK
• If the filter cartridge is fastened too much, the packing will be damaged and this leads to leakage of
fuel. If the filter cartridge is too loose, fuel will also leak from the packing. Therefore, be sure to observe
the tightening angle.
• When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
14. Confirm that drain plug (8) at the bottom of transparent cup (6) is tightened securely.
15. Install hose (5).
16. Remove the vinyl bag wrapping connector (3).
17. Connect connector (3) and fix the sensor harness with clip (4).
4-52
REMARK
• If water gets on the connector, the sensor may malfunction and the water separator caution lamp may
light up. When removing the connector, be extremely careful not to let water attach to the connector.
• If water attaches to the connector, dry it completely before connecting it.
OPEN position (O).
19. Bleed air.
1) Fill the fuel tank with fuel (to the F mark of the fuel lev-
el gauge).
2) Insert the key into the starting switch and turn it to ON

position (B).
3) Hold the key in ON position (B) for 30 seconds.
4) Then, return the key to OFF position (A) and hold it

5) Repeat above steps 2) to 4) 4 times.
20. Turn the starting switch key to START position (C) and
start the engine.
21. Check the filter seal surface and the mounting face of the
water separator for fuel leakage.
22. Run the engine at low idle for approximately10 minutes.
METHOD FOR REPLACING ELEMENT ON POWER TRAIN OIL FILTER

k WARNING
Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Prepare a filter wrench and a container to catch the oil.
4-53
1. Open the battery inspection cover at the rear left of the

machine.
2. Place a container under the filter cartridge to catch the
fuel.
5. Coat the seal surface and thread portion of the new filter
cartridge with clean oil, then install it.
6. After the sealing surface reaches the filter head, tighten
the filter cartridge 2/5 turns with the filter wrench.
METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC FILTERS

Since the filtering ability of the filters decreases as they are aged, replace them every 500 operating hours or
every year.
METHOD FOR REPLACING RECIRCULATION AIR FILTER

1. Remove knob (1) at the rear left in the cab, and remove
bracket (2).
2. Remove the recirculation air filter from bracket (2).
3. Replace the recirculation air filter with new one.
4. Install bracket (2) and install knob (1).
METHOD FOR REPLACING FRESH AIR FILTER

1. Open battery inspection cover (1) at the rear left of the ma-
chine, and lock it open.
2. Remove grease pump (2).
3. Loosen knob (3) and remove upper cover (4).
4-54
4. Remove fresh air filter cover (5).
5. Remove fresh air filter (6).

6. Remove soil and sand from the sealing surface of fresh air
filter covers (5) and inside of the filter cases.
7. Install the new fresh air filter.
REMARK
The fresh air filter has thin side (S) and thick side (L).
Install the fresh air filter with thick side (L) down.
8. Install fresh air filter covers (5).

Install fresh air filter cover (5) so that air intake port (A) faces the outside of the machine.
9. Install grease pump (2).
10. Install upper cover (4) and tighten knob (3).
11. Close door (1) of the battery inspection cover at the left rear of the machine.

Maintenance for every 50, 250 and 500 hours should be performed at the same time.
METHOD FOR CHANGING OIL IN POWER TRAIN CASE, CLEAN POWER TRAIN
PUMP STRAINER AND SCAVENGING PUMP STRAINER
k WARNING
• Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in-
jury. Accordingly, wait until they have cooled down before starting the work.
• The undercover is a heavy part (22 kg). Do not open or close the cover just under it. When removing
bolts (3), perform the work from the rear of the cover so that you can easily get out of the way.
Refill capacity: 48 ℓ
4-55
1. Remove cover (1) on the lower rear side of the machine.
2. Place the oil container to catch oil under drain plug (P)
(with a slit).
3. Loosen drain valve (P1) (with a slit) and drain the oil.
4. After draining the oil, tighten drain plug (P).

chine.
machine.

(B) Dangerous place
6. Place the oil container to catch oil under cover (5).

7. Loosen mounting bolts (4) of the power train pump strain-
er, and remove cover (5).
4-56
8. Take out spring (6) and then take out strainer (7).
9. Remove all dirt from strainer (7), then wash it in clean die-
At this time, clean the case interior and the removed parts
as well.
10. Loosen mounting bolts (8) of the scavenging pump strain-

er, and remove cover (9).
11. Take out spring (10) and then take out strainer (11).
12. Remove all dirt from strainer (11), then wash it in clean die-
At this time, clean the case interior and the removed parts
as well.
13. Install the spring and strainer.
If the spring or strainer is damaged, replace them.
14. Replace the power train oil filter element.
For detail, see “METHOD FOR REPLACING ELEMENT ON POWER TRAIN OIL FILTER (4-53)”.
15. Open the inspection window on the right side of the ma-
chine.
16. Add the refill capacity of oil through oil filler port (F).
17. After adding the oil, check that the oil level is proper.
For the checking method, see “METHOD FOR CHECKING
OIL LEVEL IN POWER TRAIN CASE AND ADDING OIL
(3-137)”.
18. Close the inspection window on the right side of the ma-
chine.
METHOD FOR CHANGING OIL IN FINAL DRIVE CASE

k WARNING
• If there is remaining pressure inside the case, the oil or plug may jump out. Loosen the plug slowly
to release the pressure.
Refill capacity:
D65EX (other than power angle power tilt dozer): 16.5 ℓ
D65EX (power angle power tilt dozer), D65PX, D65WX: 22 ℓ each on right and left sides
Prepare containers to catch drained oil.
4-57
1. Stop the machine so that drain plug (1) is directly at the

bottom.
2. Place the oil containers to catch oil under drain plugs (1)
and (4).
3. Remove oil level plug (2) and oil filler plug (3).
4. Remove drain plugs (1) and (4) and drain the oil.
5. After draining the oil, install drain plugs (1) and (4).
6. Add oil through the hole of oil filler plug (3).
7. After adding the oil, check that the oil level is proper.
For the check of oil level, see “METHOD FOR CHECKING
OIL LEVEL IN FINAL DRIVE CASE, ADDING OIL (4-45)”.
8. Install oil level plug (2) and oil filler plug (3).
METHOD FOR REPLACING FUEL MAIN FILTER CARTRIDGE

Prior to this, perform “METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE (4-51)” of EVERY 500
HOURS MAINTENANCE.
k WARNING
• Immediately after the engine is stopped, all parts are still very hot, so do not replace the filter imme-
diately. Wait until all of parts cool down before starting the work.
• High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.
• Do not bring any open flame close.
NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing parts, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu-
ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Never use a substitute.
• When performing the inspection or maintenance of the fuel system, pay more attention than normal
to the entry of dirt. If dirt sticks to any part, use fuel to wash it off completely.
Prepare a filter wrench and a container to catch the fuel.
1. Open the inspection cover at the bottom of the fuel tank.
4-58
2. Turn fuel supply valve (1) of the fuel tank to CLOSE posi-
tion (C).
3. Open the engine side cover on the left side of the ma-
chine.
4. Remove bolts (2) (2 pieces) and remove underside cover
(3).
5. Place a container under filter cartridge (4) to catch the fuel.

NOTICE
• Do not fill the new filter cartridge with fuel.
• Remove cap (B) at center and install the filter car-
tridge.

8. Thinly apply oil to the packing surface of the new filter car-
tridge, then install the filter cartridge to the filter head.
Replace inner seal (5) with a new one.
9. After the packing surface reaches the sealing surface of
the filter head, tighten the filter cartridge 3/4 turns.
REMARK
If the filter cartridge is fastened too much, the packing will
be damaged and this leads to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing.
Therefore, be sure to observe the tightening angle.
4-59
OPEN position (O).
11. Bleed air.
1) Fill the fuel tank with fuel (to the F mark of the fuel lev-
el gauge).
2) Insert the key into the starting switch and turn it to ON

position (B).
3) Hold the key in ON position (B) for 30 seconds.
4) Then, return the key to OFF position (A) and hold it

5) Repeat above steps 2) to 4) 4 times.
6) Turn the starting switch key to START position (C) and

start the engine.
12. Check the filter seal surface for fuel leakage.

If the leakage is noticed, check the filter cartridge for its tightening condition.
If oil still leaks, remove the filter cartridge and check it.
If the packing surface has damage or foreign material on it, replace the cartridge with a new one.
METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT

NOTICE
Note that the fuel tank breather and hydraulic tank breather have different part numbers.
(The element is common to both. For detail, see “CONSUMABLE PARTS (7-3)”.)
4-60

fuel tank.
3. Replace breather element (4) with a new one.
For replacement of the hydraulic tank breather element, see “METHOD FOR REPLACING HYDRAULIC TANK
BREATHER ELEMENT (4-62)”.
METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE

CLAMPS
Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger -
aftercooler - engine.
METHOD FOR CLEANING POWER TRAIN CASE BREATHER

1. Remove bolts (1) of step.
2. Remove step (2).
5. Remove breather (5).
6. Rinse breather (5) in clean diesel fuel or flushing oil, and
remove dirt from inside.
4-61
METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT

NOTICE
Note that the fuel tank breather and hydraulic tank breather have different part numbers.
(The element is common to both. See “CONSUMABLE PARTS (7-3)”.)
hydraulic tank.
3. Replace breather element (4) with a new one.
METHOD FOR REPLACING DEF TANK BREATHER ELEMENT

k WARNING
Do not replace the element immediately after engine is stopped.
NOTICE
• Komatsu recommends using Komatsu genuine parts for replacement parts.
• If the machine is operated without DEF tank breather element attached, or with the element other
than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which
will cause failure of the machine. Never operate the machine without DEF tank breather element at-
tached, nor use the element other than Komatsu genuine parts.
• Do not flush DEF tank breather element. Flushing or regenerating of it will degrade the performance
of element, and will cause the breakage of DEF tank. Never reuse the DEF element.
• Always stop the engine and clean around DEF tank before replacing.
• After the engine is stopped, DEF system devices automatically purge DEF in DEF injector and DEF
pump and return it to DEF tank to prevent malfunction of the devices caused by freezing of DEF or
deposition of urea.
After the engine is stopped, the devices are operated for a few minutes. Replace the element after
DEF system devices stop.
• Improper assembly of DEF tank breather element may cause leakage of DEF. Replace the element in
the correct procedure.
4-62

battery cover.
3. Replace breather (4) with a new one.
METHOD FOR CHECKING OIL LEVEL IN DAMPER CASE AND ADDING OIL
k WARNING
• Immediately after the engine is stopped, its parts and
oil are still very hot and may cause burn injury. Ac-
cordingly, wait until they have cooled down before
starting the work.
• The undercover is a heavy part (22 kg). Do not open or
close the cover just under it.
When removing bolts(2), perform the work from the
rear of the cover so that you can easily get out of the
way.
Check the oil level while the engine is stopped.

Low oil level in the damper case can cause seizure. Stop the machine on a flat place and check it.
1. Stop the engine.
chine.
(B) Dangerous place
machine.
3) Lower and open the undercover gradually.
4-63
3. Remove oil level plug (3) and check the oil level.
• When the oil level is near the lower edge of the plug
hole
The oil level is proper. Install oil level plug (3).
• When the oil level is far below the lower edge of the
plug hole
Add oil.
1) Remove oil filler plug (4).
2) Add new oil through the oil filler port until the oil level
reaches the bottom edge of oil level plug (3).
3) After adding oil, install oil level plug (3) and oil filler
plug (4).
METHOD FOR CHECKING FOR LOOSE ROPS MOUNT BOLTS

Check that bolts (1) for looseness or damage. (4 pieces each
on the right and left sides)
• When any bolt is loose
Tighten the bolt.
Tightening torque: 245 to 309 Nm {25 to 31.5 kgm}
• When any bolt is damaged
Replace the bolt with a Komatsu genuine part.

Maintenance for every 50, 250, 500 and 1000 hours service should be performed at the same time.
METHOD FOR CHANGING OIL IN DAMPER CASE

k WARNING
• Immediately after the engine is stopped, its parts and
oil are still very hot and may cause burn injury. Ac-
cordingly, wait until they have cooled down before
starting the work.
• The undercover is a heavy part (22 kg). Do not open or
close the cover just under it.
When removing bolts(2), perform the work from the
rear of the cover so that you can easily get out of the
way.
• When removing drain plug (5) of the damper case, take
care not to get oil over yourself.
Refill capacity: 1.7 ℓ

4-64

chine.
(B) Dangerous place
machine.
2. Remove oil level plug (3) and oil filler plug (4).
3. Place the oil container to catch oil under drain plug (5).
4. Remove drain plug (5) and drain the oil.
5. After draining the oil, install drain plug (5).
6. Add new oil through the oil filler port until the oil level rea-
ches the bottom edge of oil level plug (3).
7. After adding oil, install oil level plug (3) and oil filler plug
(4).
METHOD FOR CHANGING OIL IN HYDRAULIC TANK, REPLACING HYDRAULIC

OIL FILTER ELEMENT, AND CLEANING HYDRAULIC TANK STRAINER
k WARNING
• When the oil filler cap is removed, oil may spout out. Turn the cap slowly to release the internal
pressure, then remove it carefully.
Refill capacity: 62 ℓ
4-65
1. Lower the work equipment to the ground and stop the en-
gine.
2. Loosen the cap of oil filler port (F) slowly on the top of the
hydraulic tank to release the internal pressure in the hy-
draulic tank.
3. Remove the cap.
4. Remove cover (1) on the bottom of the hydraulic tank.
5. Place the oil container to catch oil under drain valve (2).
6. Loosen drain valve (2) and drain the oil.

When loosening drain valve (2), be careful not to get oil on
yourself.
7. Close drain valve (2).
8. Install cover (1).

11. Take out spring (5), valve (6), and element (7).
12. Clean the inside of the case.
13. Clean removed spring (5) and valve (6).
14. Install new element (7), valve (6), and spring (5).
15. Install cover (4).
16. Install bolts (3).
19. Remove strainer (10).
20. Clean removed strainer (10) in clean diesel fuel or flushing
oil.
21. Install strainer (10) to its original position.
22. Add the refill capacity of oil through oil filler port (F).
23. Install the cap of oil filler port (F).
24. Check that the oil level is proper.
For the check of oil level, see “METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING
OIL (3-134)”.
4-66
METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRES-

SURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)
k WARNING
The accumulator is charged with high-pressure nitrogen gas, so improper operation may cause an ex-
plosion, which will lead to serious injury or death. For handling, always observe the following.
• The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic
equipment, do not stand in the direction that the oil spurts out when performing the operation. In
addition, loosen the bolts slowly when performing the work.
• Do not disassemble it.
• Do not bring open flame close to it or do not dispose of it in fire.
• Do not perform drilling, welding or flame-cutting.
• When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per-
formed.
NOTICE
If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes
impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma-
chine.
FUNCTION OF ACCUMULATOR
The accumulator (1) stores the pressure in the control circuit.
Even after the engine is stopped, the control circuit can be op-
erated, so the following actions are possible.
• If the control lever is operated in the direction to lower the
work equipment, it is possible for the work equipment to go
down under its own weight.
• The pressure in the hydraulic circuit can be released.
METHOD FOR CHECKING FUNCTION OF ACCUMULATOR

k CAUTION
When operating the blade control lever to lower the blade, check the safety around the machine.
NOTICE
If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes
chine.
Replace the accumulator every 2 years or every 4000 hours, whichever comes sooner.
Check the nitrogen gas charge pressure as follows.
1. Stop the machine on a firm and flat ground.
4-67
2. Set the parking brake lever (1) to LOCK position (L).
3. Raise the work equipment (blade) to the upper limit.
NOTICE
Perform the following procedure (for lowering the blade to the ground) within 15 seconds after stopping
the engine.
When the engine is stopped, the pressure inside the accumulator gradually goes down, so this inspec-
tion can be performed only immediately after the engine is stopped.
4. With the work equipment at the upper limit, turn the start-
ing switch to OFF position (A), and stop the engine.
4-68
6. Set the work equipment lock lever (2) to FREE position

(F).
7. Operate the blade control lever fully in the direction to low-

er the blade.
8. Check that the work equipment goes down to the ground
under its own weight.
In the following cases, the gas charge pressure of the accumulator has gone down. Contact your Komatsu dis-
tributor.
• Work equipment does not go down
• Stops while going down
METHOD FOR RELEASING PRESSURE IN HYDRAULIC CIRCUIT

NOTICE
Finish the steps of operating the blade control lever to the front and back, and to the right and left, to
each stroke end within 15 seconds after the engine has stopped.
After the engine stops, pressure inside the accumulator begins to gradually go down, so the pressure
cannot be released except right after the engine stops.
1. Lower the work equipment to the ground and stop the engine.
2. Turn the starting switch to ON position.
3. Set the work equipment lock lever (1) to FREE position.
4. Operate the blade control lever fully to the front, rear, left, and right to release the pressure from the hy-
draulic circuit.
4-69
In order to release pressure from the ripper hydraulic cir-

cuit, operate the ripper control lever to the right and left to
each stroke end.
(a) RAISE
(b) HOLD
(c) LOWER
(d) FLOAT
(A) Tilt RIGHT
(B) Tilt LEFT
5. Set the work equipment lock lever (1) to LOCK position.
METHOD FOR CHECKING ALTERNATOR

Ask your Komatsu distributor to have the alternator checked.
If the engine is started frequently, have this inspection performed every 1000 hours.
METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE

Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work.
METHOD FOR REPLACING KCCV FILTER ELEMENT

k WARNING
After the engine has been operated, all of parts are still very hot. Do not replace the filter element imme-
diately. Wait until all of parts cool down before starting the work.
NOTICE
• If the engine is operated without the filter element, the turbocharger and aftercooler become dirty
and their performance will lower and that can cause engine problems such as overrun caused by
suction of oil. Therefore, do not start the engine without the filter element.
• The filter element cannot be flushed. Flushing or regenerating of the filter element will degrade per-
formance of the filter. As a result, the turbocharger and aftercooler become dirty and the perform-
ance lowers or the crankcase pressure increases. Never reuse the filter element since it can cause
an engine failure.
• After the filter element is replaced, if KCCV is not assembled correctly, oil or blowby gas may leak.
Replace the filter element in the correct procedure.
• Always stop the engine and clean around the KCCV before replacing the element.
Prepare the special wrench for KCCV and a container to catch the oil.
4-70
The KCCV ventilator is located in the positions shown in the

figure.
For the use of the special wrench, see the figure.
1. By using the special wrench, loosen ring (3) of KCCV ven-

tilator (1).
2. After ring (3) comes off, remove case (4) from body (2) and
remove element (5).
There may be oil accumulated or sticking in the case and
element. Take care not to spill the oil when replacing the
element.
REMARK
When the ambient temperature is low, water or emulsified
matter may stick to the inside of KCCV because of con-
densation of water vapor in the blowby gas. However, as
far as the coolant level is normal, it is not a problem.
3. Remove used O-ring (6) sticking to case (4) and install a
new O-ring contained in the service kit.
Apply engine oil to the new O-ring.
4-71
4. While matching ◇ marks (7) of the new element with ◇

mark (8) of the case, insert the element firmly into the end
of the body.
When inserting, take extreme care so that protrusion (9) in
the case is joined together with rubber lip (10) of the ele-
ment.
5. Align the position of ◇ mark (8) on the case with that of ◇

mark (11) of the filter body label, then install the case to
the filter body.
The element can be installed only when its claw (12) and
claw (13) of the case are correctly inserted in groove (14)
of the body. Bases (15) and (16) are oval. Take extreme
care so that those bases are matched with each other.
6. Fit ring (3) to the threaded part of the body and tighten it
with the hand firmly until it stops.
4-72
7. By using the special wrench, further tighten the ring 1/15 to

2/15 turns (1 to 2 ridges of the ring).
If the engine is operated with the ring tightened insufficient-
ly, oil and blowby gas may leak.
8. Check the KCCV hose for leakage, crack, and loose
clamp.
Replace as necessary.
METHOD FOR REPLACING DEF FILTER

k WARNING
Immediately after the engine is stopped, the parts are still very hot. Do not replace the filter immediately.
Wait until all of parts cool down before starting the work.
NOTICE
• If the machine is operated without DEF filter attached, or with the filter other than Komatsu genuine
parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the
machine. Never operate the machine without DEF filter attached, nor use the filter other than Komat-
su genuine parts.
• DEF filter cannot be flushed. Flushing or regenerating of it will degrade the performance of filter,
and will cause the breakage of DEF tank. Never reuse the filter.
• Improper assembly of DEF filter may cause leakage of DEF. Replace the DEF filter in the correct pro-
cedure.
• DEF freezes at –11 °C. If it is frozen, replacement of the filter becomes difficult. Replace the filter
when the temperature around DEF pump is higher than -11 °C, and in the condition that DEF is not
frozen.
After the engine is stopped, DEF system devices automatically purge DEF in DEF injector and DEF pump and
return it to DEF tank to prevent malfunction of the devices caused by freezing of DEF or deposition of urea.
After the engine is stopped, the devices are operated for a few minutes. Before replacing the filter, clean around
the DEF pump first after DEF system devices stop.
Items to be prepared
• DEF filter removal tool
The DEF filter is located at the positions shown in the figure.
Before replacing DEF filter, prepare the following.
• Remove grease pump (A) and grease pump holder (B).
• Remove mounting bolts (C), and move fuel prefilter (D) to-
ward the front of the machine.
4-73
1. Remove filter cap (1) at the bottom of DEF pump, and re-
move equalizing element (2).
2. Turn cap (4) of filter removal tool (3) and remove it.
3. Check the installation of spacer (5).
4. Insert filter removal tool (3) into the bottom of the DEF
pump and thrust in with hand.
5. Check that filter removal tool (3) is fully inserted to the end.
Insert the filter removal tool to the end where you cannot
thrust it in any further.
6. Turn filter removal tool (3) in reverse, and remove filter (6).
Filter (6) is removed and you can take it out together with
filter removal tool (3).
If filter (6) cannot be removed from DEF pump, grip filter
removal tool (3), pull it down, then it will be removed.
4-74
7. Slide filter (6) down, and remove spacer (5) from filter re-
moval tool (3).
8. Pull filter (6) up while pushing in the tip of filter removal

tool (3), and remove it.
9. Return the removed spacer (5) to filter removal tool (3),
and keep them.
10. Insert a new filter and a new equalizing element into the
bottom of DEF pump, and lightly tighten them with hand.
11. Tighten filter cap (1).


Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be performed at the same time.
REPLACE DEFINED LIFE PARTS

Material quality of these parts can change as time passes and they are likely to wear out or deteriorate.
Replace them every 2 years or every 4000 hours, whichever comes sooner.
4-75
DEFINED LIFE PARTS LIST

No. Periodical replacement parts
1 Fuel system Fuel hose
Spill hose
2 Engine lubrication Turbocharger lubrication hose
system Engine oil filter hose
3 Work equipment hy- Work equipment pump delivery hose
draulic system
Work equipment pump LS hose
Hydraulic drive fan hose (Intake fan)
HSS line hose Ask your Komatsu distributor for re-
Suction hose placement.
External work equipment hose

• Blade lift hose
• Blade tilt hose
• Blade pitch hose
• Blade angle hose
• Ripper lift hose
4 Others PPC accumulator
METHOD FOR CHECKING WATER PUMP

Check around the water pump for water leakage.
If any abnormality is found, ask your Komatsu distributor for repair or replacement of the parts.
METHOD FOR CHECKING STARTING MOTOR

Ask your Komatsu distributor to have the starting motor checked.
If the engine is started frequently, have this inspection performed every 1000 hours.
METHOD FOR REPLACING ACCUMULATOR (FOR CONTROL CIRCUIT)

k WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an ex-
plosion, which will lead to serious injury or death, or damage. For handling, always observe the follow-
ing.
• The pressure in the hydraulic circuit cannot be completely removed. When removing the hydraulic
equipment, do not stand in the direction that the oil spurts out when performing the operation. In
addition, loosen the bolts slowly when performing the work.
• Do not disassemble.
• Do not bring open flame close to it or do not dispose of it in fire.
• Do not perform drilling, welding or flame-cutting.
• When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per-
formed.
NOTICE
If the nitrogen gas charge pressure in accumulator (1) is low and operations are continued, it becomes
chine.
Ask your Komatsu distributor to replace it.
4-76
Replace the accumulator every 2 years or every 4000 hours,

whichever comes sooner.
METHOD FOR CHECKING FOR LOOSENESS OF ENGINE HIGH-PRESSURE PIP-

ING CLAMP, HARDENING OF RUBBER
NOTICE
If the engine operation is continued while any bolt is loosened or any rubber is hardened or removed,
the contact portions of the high-pressure piping may be worn and may be broken by vibration. Always
check that the proper high-pressure piping clamps are correctly installed.
Check clamps (1) to (4) visually and with your fingers that there
are no loose bolts or hardening of the rubber.
If there is any loose bolt or hardened rubber, ask your Komatsu
distributor for replacement.
4-77
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,

HARDENING OF RUBBER
The fuel spray prevention caps act to prevent the fuel from coming into contact with high-temperature parts of
the engine and causing a fire if the fuel should leak or spray out.
Check the fuel spray prevention caps visually or with a finger to see if any of them has slipped off, or the rubber
portion is hardened.
4-78
If there is any loose bolt or hardened rubber, ask your Komatsu distributor for replacement.

Maintenance for every 50, 250 and 500 hours should be performed at the same time.
METHOD FOR CLEANING KDPF

Contact your Komatsu distributor for cleaning of the KDPF.
METHOD FOR CLEANING DEF TANK

Ask your Komatsu distributor for cleaning of the DEF tank.
METHOD FOR CLEANING DEF TANK MOUNTING PORTION

Ask your Komatsu distributor for cleaning of the mounting portion of the DEF tank.

Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be performed at the same time.
METHOD FOR REPLACING FUEL SPRAY PREVENTION CAP

Ask your Komatsu distributor for replacement of the fuel spray prevention caps.

Maintenance for every 50, 250, 500, 1000 and 4500 hours service should be performed at the same time.
4-79
METHOD FOR REPLACING DEF HOSE

Ask your Komatsu distributor for replacement of the DEF hose.
END OF SERVICE LIFE

• For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor.
4-80
SPECIFICATIONS
5-1
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
D65EX-18 SPECIFICATIONS
With ROPS cab, air conditioner
D65EX-18
D65EX-18 D65EX-18
Item Unit Power angle power tilt
Sigma dozer Straight tilt dozer
dozer
20070 19740 21770
Machine weight kg
[20470] [20140] [22180]
Engine model - Komatsu SAA6D114E-6 diesel engine
SAE J1995
164 / 1950
(Gross)
Rated kW/
horse- ISO 14396 164 / 1950
power min-1
ISO 9249/SAE J1349
162 / 1950
(Net)
Rear work equipment - Hitch Hitch Counterweight
Type, width of shoe mm Single, 510 Single, 510 Single, 560
A Overall length mm 5490 5330 5790
3155
B Overall height mm
[3160]
C Overall width mm 3410 3415 3870
Travel speed Forward km/h 3.6/5.6/7.3/11.3
(1st/ 2nd/ 3rd(Low)/ 3rd) Reverse km/h 4.5/6.7/8.7/13.6
Ambient temperature working range
°C -20 thru 50
for operation and storage
[ ]: Machines equipped with PLUS type track shoe
D65PX-18 SPECIFICATIONS
5-2
D65PX-18
D65PX-18
Straight tilt dozer
dozer
21550 22420
Machine weight kg
[22020] [22880]
SAE J1995
164 / 1950
(Gross)
Rated kW/
horse- ISO 14396 164 / 1950
power min-1
ISO 9249/SAE J1349
162 / 1950
(Net)
Rear work equipment - Hitch Hitch
Type, width of shoe mm Single, 915 Single, 760
A Overall length mm 5680 5790
3155
B Overall height mm
[3160]
C Overall width mm 3970 4010
°C -20 thru 50
D65WX-18 SPECIFICATIONS
D65WX-18
D65WX-18
SIGMA dozer
dozer
20920 22670 (49987)
Machine weight kg
[21360] [23110 (50958)]
5-3
D65WX-18
D65WX-18
SIGMA dozer
dozer
SAE J1995
164 / 1950
(Gross)
Rated kW/
horse- ISO 14396 164 / 1950
power min-1
ISO 9249/SAE J1349
162/ 1950
(Net)
Rear work equipment - Hitch Counterweight
Type, width of shoe mm Single, 760 Single, 760
A Overall length mm 5500 5790
3155
B Overall height mm
[3160]
C Overall width mm 3580 4010
°C -20 thru 50
5-4
ATTACHMENTS AND OP-
TIONS
6-1
GENERAL PRECAUTIONS ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS
PRECAUTIONS FOR SAFETY
If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of
the machine, but will also cause problems with safety.
When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distrib-
utor first. If you do not contact Komatsu, we cannot accept any responsibility for any accidents or failures.
k WARNING
General precautions
• Read the instruction manual for the attachment carefully, and you must understand the operation
method completely before using the machine..
If you lose the instruction manual, be sure to order another copy from your Komatsu distributor.
• To prevent serious personal injury or death caused by misoperation, you must not place your foot
on the pedal except when operating the pedal.
Precautions for removal and installation
When removing or installing an attachment, observe the following items and work safely.
• Select a firm, level surface when installing or removing an attachment.
• When working in cooperation with one or more other workers, decide signs and observe them when
performing the operation.
• Use a crane when carrying heavy objects (more than 25 kg).
• When removing a heavy part, always place a support in position before removing it.
When lifting a load with a crane, be particularly careful of the center of gravity.
• It is dangerous to perform works when the load has been raised by a crane. Always lower the load
onto a stand and check that it is safe.
• When leaving an attachment removed or installing it, place it in a stable position to prevent it from
falling over.
• Never go under a load raised by a crane.
Always stand in a place which is safe even if the load should fall.
NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified
person.
For details of removal and installation operations, contact your Komatsu distributor.
6-2
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER
HANDLE HYDRAULIC RIPPER

This ripper is applicable for D65EX and D65WX dozers.
GENERAL VIEW
(1) Hydraulic cylinder (4) Shank

(2) Link (5) Point
(3) Beam (6) Support
EXPLANATION OF COMPONENTS
RIPPER CONTROL LEVER
k WARNING
When performing inspection or maintenance of the machine, or when parking the machine, lower the
ripper to the ground and set the work equipment lock lever to LOCK position.
6-3
HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS
The ripper control lever is used for operating the ripper.

(a) RAISE: Ripper goes up
(b) HOLD: Ripper is stopped and held in this position.
(c) LOWER: Ripper goes down
REMARK
If the work equipment lock lever (1) is set to LOCK position (L),
the operation of the ripper is locked. For details of the operation
of the work equipment lock lever, see “WORK EQUIPMENT
LOCK LEVER (3-93)”.

METHOD FOR WALK-AROUND CHECK
Check for wear of the point at the tip of the shank, check the mounting condition, and check for damage to the
pins.
If any problem is found, replace or repair it.

• Lower the ripper gradually when starting to move the machine off. Drive the machine at low speed. When
the optimum digging depth is reached, set the ripper control lever to HOLD position.
Do not dig the shank in deep when starting digging operations.
• During ripping operations, never turn the machine suddenly or travel in reverse. When turning the machine
suddenly or traveling in reverse, raise the shank from the ground surface.
• When performing digging operations with only one shank, always use the center shank. Remove both side
shanks.
• The point end touches the ground at the start of an uphill and at the end of a downhill. If the ground is hard
at this time, the ripper may be damaged. To prevent this, raise the shank to the highest position.
ADJUST WORK EQUIPMENT

METHOD FOR ADJUSTING DIGGING DEPTH
There are mounting pin holes on the shank. Select one of them, depending on the digging depth.
6-4
ATTACHMENTS AND OPTIONS HANDLE HYDRAULIC RIPPER
Max. digging depth

Pin hole position Use
( mm )
When there
is special
(A) 585
need to dig
deeply
When nor-
(B) 475
mal
When not
(C) -
using ripper
When changing the digging depth, do as follows.

1. Loosen lock plate mounting bolts(1) and remove lock plate
(2).
Lock plates (2) are at both ends of pin (3).
2. Pull out pin (3).
3. Change the position of the pin hole of the shank, and in-
stall pin (3).
4. Install lock plate (2) with bolts (1).
METHOD FOR REPLACING RIPPER POINT

A point is installed to protect the shank. If the point is worn, replace it according to the following procedure.
1. Put a pin puller to the pin indicated by the arrow, and hit it
with a hammer to drive out the pin.
The pin comes off.
2. Replace the point.
3. Insert the pin halfway.
4. Drive in the pin with the hammer.
6-5
HANDLE HYDRAULIC RIPPER ATTACHMENTS AND OPTIONS
Criteria
Standard di- Remedy
Repair limit
mension
( mm)
( mm)
Wear (a) of rip-
277 170 Replace
per point (1)
TROUBLES AND ACTIONS

OTHER TROUBLE
Lack of rising and pushing force Low hydraulic oil level Add oil to specified level.
of ripper See EVERY 250 HOURS
Slow moving MAINTENANCE.
Defective pump Check, repair. (*)
Defective adjustment of relief valve Check, adjust. (*)
Defective control valve, abnormal pressure pre- Check, repair. (*)
vention valve, or valve spool
Defective piston ring, packing, or valve Check, repair. (*)
Clogging inside piping Check, repair. (*)
Cylinder lacks holding power. Leakage of oil from piping or hose Retighten.
Defective piston ring or packing Replace. (*)
Defective piston valve Check, repair. (*)
Defective valve spool Check, repair. (*)
Defective abnormal pressure prevention valve or Check, repair. (*)
vacuum prevention valve
Oil pressure rises. Clogging inside piping Repair. (*)
Defective adjustment of relief valve Check, adjust. (*)
6-6
ATTACHMENTS AND OPTIONS HANDLE 3m WIDTH BLADE
HANDLE 3m WIDTH BLADE

This blade is applicable for D65PX and D65WX.
GENERAL VIEW
(1) Center blade (6) Lock pin

(2) Folding blade (R.H and L.H.) (7) Shim (for offset pin)
(3) Offset pin (8) Shim (for hinge pin)
(4) Hinge pin (9) Lock plate
(5) Lock plate
6-7
HANDLE 3m WIDTH BLADE ATTACHMENTS AND OPTIONS

PROHIBITED OPERATIONS
k CAUTION
• Use the 3 m wide blade for light dozing work or level-
ing work.
• Do not dig hard/frozen ground by using the right and
left folding portions of the blade or perform severe
work such as stumping, ditching, etc. by tilting the
blade.
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION PROCEDURE
As a basic rule, always transport the machine on a trailer.
When selecting the trailer, refer to the weight and dimensions shown in “SPECIFICATIONS (6-10)”.
Note that the mass and dimensions for transportation shown in “SPECIFICATIONS” depend on the types of
shoe, blade, etc.
The 3 m wide blade of this machine can be folded to reduce its width to 3 m for transportation.
METHOD FOR FOLDING BLADE

k WARNING
When folding or unfolding the blade, observe the following items.
• Place the machine on a firm and level place.
Do not park the machine on a slope.
• Place blocks 65 mm high under the right and left ends of the center blade and set the blade in a
proper condition for folding or unfolding it.
• If the control levers are touched by mistake, the machine may suddenly move, and this may lead to
a serious accident. Before folding or unfolding the blade, stop the engine and securely set the work
equipment lock lever and parking brake lever to their LOCK positions.
• When folding or unfolding the blade, stop the machine on a level place. If you remove the offset pin
on a slope, the folding blade may turn and you may be caught between the blade and track shoe.
6-8
k CAUTION
Do not tilt or angle the blade when it is folded. If you do so, the blade will interfere with the U-frame
step.
1. Stop the machine on a level ground.

2. Raise the blade and set it in parallel with the machine.
3. Place blocks 65 mm high (A) under the right and left ends
of the center blade.
4. Lower the blade slowly and set it on the blocks.
5. Remove lock pins (1) from both ends of folding blade (3).
6. Remove lock plates (2) from right and left folding blades
(3).
7. With center pin (4) installed to the center blade, rotate lock
plate (2) backward approximately 100 °.
k CAUTION
• When lock plate (6) is removed, lock pin (5) falls. Re-
move lock plate (6) with care.
• At this time, do not remove hinge pin (8) in the rear of
the blade.
8. Remove lock plate (6) of front offset pin (5).

Offset pin (5) and lock plate (6) are installed at the right,
left, top, and bottom. (4 places in total)
9. Remove offset pin (5) and shim (7) above it.
10. Rotate right and left folding blades (3) backward 180 °.
11. Match the holes for rock pin (1) so that you can lock the
blade by using lock plate (2).
12. Fix lock plate (2) and folding blade (3) by using lock pin
(1).
13. Install removed offset pins (5) (4 pieces), shims (7) (2
sets), and lock plates (6) (4 pieces) to holes (9) of center
blade (10).
REMARK
Install removed offset pins (5), shims (7), and lock plates
(6) to holes (9) to prevent them from missing.
METHOD FOR UNFOLDING BLADE

Unfold the blade in the reverse order to folding.
6-9
HANDLE 3m WIDTH BLADE ATTACHMENTS AND OPTIONS
REMARK
Install shims (2) above the upper offset pins (1) at the right and
left ends of the center blade.
CHECK AND MAINTENANCE

WHEN REQUIRED
METHOD FOR ADJUSTING PLAY IN BLADE BOSS
k WARNING
It is dangerous if the work equipment moves by mistake when the blade is adjusted.
Set the work equipment in a stable condition, then stop the engine. Securely set the work equipment
lock lever and parking brake lever to the respective LOCK positions.
NOTICE
If the wear of the center blade boss is left as it is, it becomes difficult to work stably and the machine
may be damaged.
If shims (1) and (2) in bosses (3) of the center blade are worn, folding or unfolding of the blade becomes diffi-
cult. Replace and adjust shims (1) and (2) in the bosses at both ends according to the following procedure.
1. Stop the machine on a level ground.
2. Raise the blade and set it in parallel with the machine.
3. If shims (1) and (2) at the bosses (4 places) of the center
blade are worn, remove them.
4. Measure clearances (A) and (B) in the bosses of the fold-
ing blade.
5. Insert new shims (1) and (2) so that clearances (A) and (B)
are 0 to 0.5 mm, then install pins (4).
Shim table
Shim thickness
Location No. Part No.
( mm )
(1) 21Y-70-14710 1.0
A
(2) 21Y-70-14850 2.0
(1) 21Y-70-14710 1.0
B
(2) 21Y-70-14850 2.0
SPECIFICATIONS
Power angle power tilt dozer (3m wide blade)
Item Unit D65PX-18, D65WX-18
Overall length (When unfolded) mm 4010
Overall length (When folded) mm 2990
6-10
Item Unit D65PX-18, D65WX-18

Overall blade width (When folded) mm 2960
6-11
REPLACEMENT PARTS
7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS REPLACEMENT PARTS
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS

For using the machine safely for an extended period of time, you must periodically replace the safety critical and
fire prevention-related parts listed in the table of the defined life parts.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. Howev-
er, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is
required to replace them with new ones regardless of their condition after a certain period of usage. This is im-
portant to ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the
periodic replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time
as the hoses.
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all
loose hoses and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the defined life parts.
DEFINED LIFE PARTS LIST

No. Periodical replacement parts Replacement interval
1 Fuel system Fuel hose
Spill hose
2 Engine lubrication Turbocharger lubrication hose
system Engine oil filter hose
3 Work equipment hy- Work equipment pump delivery hose
draulic system
Work equipment pump LS hose
Hydraulic drive fan hose (Intake fan)
HSS line hose Every 2 years or 4000 hours, which-
Suction hose ever comes sooner
External work equipment hose

• Blade lift hose
• Blade tilt hose
• Blade pitch hose
• Blade angle hose
• Ripper lift hose
4 Others PPC accumulator
Every 3 years from start of usage or
Seat belt 5 years after manufacturing of seat
belt, whichever comes sooner.
7-2
REPLACEMENT PARTS CONSUMABLE PARTS
CONSUMABLE PARTS
Replace consumable parts such as the filter element or air cleaner element at the time of periodic maintenance
or before they reach the wear limit. The consumable parts should be replaced correctly in order to ensure more
economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko-
matsu distributor of the machine serial number and check the latest part number when ordering parts.
CONSUMABLE PARTS
The parts in parentheses are to be replaced at the same time.
Weight Replacement inter-
Item Part No. Part name Q'ty
( kg ) val
Engine oil filter 6742-01-4540 Cartridge - 1

Power train filter 14X-49-61410 Cartridge - 1
Fuel prefilter 600-319-3610 Cartridge - 1
Every 500 hours
Fresh air filter 17M-911-3530 Element - 2
Air condi-
tioner Recirculation
20Y-979-6261 Filter - 2
air filter
Cartridge
Fuel main filter 600-319-3750 - 1
(with cap)
Hydraulic tank breather 421-60-35170 Element - 1 Every 1000 hours
DEF tank breather 421-60-35170 Element - 1
Fuel tank breather 421-60-35170 Element - 1
423-60-45461 Element - 1
Hydraulic oil filter
(07000-15160) (O-ring) - (1)
Every 2000 hours
KCCV filter 600-331-2900 Element - 1
DEF filter 6540-71-2320 Filter kit - 1
Air cleaner 600-185-5100 Element assembly - 1 -
14X-72-51810 Cutting edge (center) 38.8 1
D65EX 13G-72-61420 Cutting edge (side) 24.3 2
• Power 14Y-71-11330 End bit (left) - 1
Blade angle -
14Y-71-11340 End bit (right) - 1
power tilt
dozer (02090-11270) (Bolt) - (32)
(02290-11219) (Nut) - (32)
7-3
CONSUMABLE PARTS REPLACEMENT PARTS
Weight Replacement inter-

Item Part No. Part name Q'ty
( kg ) val

D65PX,
13G-72-61420 Cutting edge (side) 24.3 2
D65WX
• Power 14Y-71-11330 End bit (left) - 1
-
angle 14Y-71-11340 End bit (right) - 1
power tilt
(02090-11270) (Bolt) - (33)
dozer
(02290-11219) (Nut) - (33)
D65EX 14X-71-11310 Cutting edge 38.4 2
• Straight 14X-71-11330 End bit (left) - 1
tilt dozer
14X-71-11340 End bit (right) - 1 -
• Straight
tilt power (02090-11270) (Bolt) - (28)
pitch doz-
er (02290-11219) (Nut) - (28)
D65PX 14Y-71-11210 Cutting edge 45.5 2

• Straight 14Y-71-11330 End bit (left) - 1
tilt dozer
14Y-71-11340 End bit (right) - 1 -
Blade • Straight
tilt power (02090-11270) (Bolt) - (32)
pitch doz-
er (02290-11219) (Nut) - (32)
144-70-11131 Cutting edge 45.5 2
D65EX 14X-71-11330 End bit (left) - 1
• Angle 14X-71-11340 End bit (right) - 1 -

dozer (02090-11270) (Bolt) - (32)
(02290-11219) (Nut) - (32)
D65EX 14X-952-5120 Cutting edge (left) 9.1 1
• Sigma
14X-952-5190 Cutting edge (right) 9.1 1
dozer
• Sigma 14X-952-5550 End bit (left) 22.6 1 -
power 14X-952-5560 End bit (right) 22.6 1
pitch doz-
er (02090-11270) (Bolt) - (32)
(02290-11219) (Nut) - (32)
14X-952-5180 Cutting edge (left of center) 25.7 1
D65WX 14X-952-5381 Cutting edge (right of center) 30.4 1
• Sigma 14X-952-5120 Cutting edge (left) 9.1 1

dozer 14X-952-5190 Cutting edge (right) 9.1 1
Blade • Sigma -
14X-952-5550 End bit (left) 22.6 1
power
pitch doz- 14X-952-5560 End bit (right) 22.6 1
er (02090-11270) (Bolt) - (33)
(02290-11219) (Nut) - (33)
7-4
REPLACEMENT PARTS CONSUMABLE PARTS
NOTICE
When handling parts that weigh more than 25 kg, remember that they are heavy objects, and take the
necessary care.
7-5
RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS
RECOMMENDED FUEL, COOLANT, AND LUBRICANT

NOTICE
• Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu construc-
tion equipment and components.
In order to keep your machine in the best condition for long period of time, it is essential to follow
the instructions in this Operation and Maintenance Manual.
• Failure to follow these recommendations may result in shortened life or excessive wear of the en-
gine, power train, cooling system, and/or other components.
• Commercially available lubricant additives may be good or bad for the machine. Komatsu does not
recommend any commercially available lubricant additive.
• Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komat-
su genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect
the engine such as deteriorated oil may reduce lubricating function, and it may cause failure, short-
ening of the machine life, lowering of performance and increase of fuel consumption.
• Use the fuel, the oil and the lubricant according to the ambient temperature as recommended.
• If the machine is operated at a temperature of -20 °C and below, separate devices are needed, so
consult your Komatsu distributor.
NOTICE
The fuel used must be ultra low-sulfur diesel fuel.
(≤10 ppm)
To ensure good fuel consumption characteristics and ex-
haust gas characteristics, the engine mounted on this ma-
chine uses an electronically controlled high-pressure fuel
injection device and emission gas control system (KDPF).
Since the high-pressure fuel injection device requires high
precision parts and lubrication, if low viscosity fuel with
low lubricating ability is used, its durability may drop con-
siderably. And using fuel with high sulfur content can dete-
riorate the engine parts and KDPF catalyzer, inducing fail-
ures, decrease of the life and degradation in performance.
NOTICE
Use DEF as the aqueous urea solution for SCR system.
DEF is a colorless transparent 32.5 % aqueous urea solu-
tion.
The quality of DEF is prescribed in ISO22241-1. Always use
DEF that conforms to this quality standard.
LUBRICATION CHART
• The lubrication chart uses symbols to show the lubrication points and types of lubricant by each lubrication
interval.
• Even if the same symbol is used in the lubrication chart, the recommended genuine oil may differ according
to the lubrication points and the ambient temperature. For details, see “METHOD FOR USING FUEL
COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (7-9)”.
• For details of lubrication, see “MAINTENANCE SCHEDULE (4-13)”.
7-6
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT
Straight tilt dozer, sigma dozer, straight tilt power pitch dozer, sigma power
pitch dozer, and angle dozer
7-7
Power angle power tilt dozer
• The symbols used in the lubrication chart are explained as follows.
Symbols used in the lubrication standard chart

Symbol Meaning of symbol Symbol Meaning of symbol
Read Operation and Maintenance Manual Supply grease
Change engine oil Check engine oil level
Change hydraulic oil Check hydraulic oil level
Change power train oil Check power train oil level
Replace engine oil filter Replace hydraulic oil filter
Replace hydraulic tank breather element Replace fuel filter
Replace KCCV filter Replace power train oil filter
Replace power train case breather

Replace fuel tank breather element
7-8
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT
Replace DEF filter

Replace DEF tank breather element
METHOD FOR USING FUEL COOLANT AND LUBRICANTS ACCORDING

TO AMBIENT TEMPERATURE
Ambient Temperature, degrees Celsius Recommended Komatsu
Reservoir Fluid Type
Min Max Fluids
Engine oil for EOS5W30-LA

KDPF used in -25 °C 35 °C (KES Diesel Engine Oil)
cold terrain (Oil (Note 1)
Change interval
EOS5W40-LA
250 hours)
-25 °C 40 °C (KES Diesel Engine Oil)
Engine oil pan (Note 1)
Engine oil for EO10W30-LA

-20 °C 40 °C
KDPF (Oil (KES Diesel Engine Oil)
Change interval EO15W40-LA
500 hours) -15 °C 50 °C
(KES Diesel Engine Oil)
Damper case Idler TO30
Power train oil -30 °C 50 °C
(each) (KES) (Note 2)
TO10
-30 °C 10 °C
(KES)
Power train case Power train oil
TO30
0 °C 50 °C
(KES)
Final drive case TO30
Power train oil -30 °C 50 °C
(each) (KES)
TOS5W30
-30 °C 50 °C
(KES)
Power train oil
TO10
Hydraulic system -20 °C 50 °C
(KES)
HO46-HM
Hydraulic oil -20 °C 50 °C
(KES)
G2-TE
Hyper grease -20 °C 50 °C
(KES) (Note 3)
Grease fitting
Lithium EP G2-LI
-10 °C 50 °C
grease (KES)
Non-Amine En-
AF-NAC
Cooling system gine Coolant -30 °C 50 °C
(KES) (Note 4)
(AF-NAC)
-30 °C 20 °C EN Class 2
Fuel tank Diesel fuel
0 °C 50 °C EN Grade B
DEF tank DEF -30 °C 50 °C DEF (Note 5)
7-9
Final drive case Cooling

Idler Hy- (each of right and system
Power left)
Engine Damper (each of draulic Fuel (includ- DEF
train
oil pan case right oil sys- tank ing res- tank
case EX (oth- EX
and left) tem ervoir
er than (PAT),
PAT) PX, WX tank)
Speci-
fied
ℓ 34.5 1.7 0.25 89 53 16.5 22.2 415 49 34.7
ca-
pacity
Refill
ca- ℓ 30.5 1.7 0.25 62 48 16.5 22.2 - - 23.5
pacity
REMARK
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity
means the amount of oil needed to refill the system during inspection and maintenance.
Note 1: KDPF engine oil for cold district is deteriorated easily than that for normal area (replace every 500
hours), so replace oil and filter cartridge every 250 hours. For changing maintenance time of machine monitor,
ask your Komatsu distributor to perform the work.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper white grease (G2-T, G2-TE) has a high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-T or G2-TE is recommended.
Note 4: Non-Amine Engine Coolant (AF-NAC)
1. The coolant has the important function of preventing corrosion as well as preventing freezing.
cause serious problems in the cooling system, including the engine.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant
(AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for
2 years or 4000 hours.
Non-Amine Engine Coolant (AF-NAC) is strongly recommended wherever available.
2. For details of the density of Non-Amine Engine Coolant (AF-NAC), see “METHOD FOR CLEANING INSIDE
OF COOLING SYSTEM (4-19)”.
Non-Amine Engine Coolant (AF-NAC) is supplied already diluted. In this case, fill up the tank with pre-dilut-
ed fluid. (Never dilute the Non-Amine Engine Coolant with ordinary water.)
Note 5: DEF freezes at -11 °C. If thawing is necessary, DEF system is automatically heated and thawed after
the engine is started.
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU

GENUINE OILS
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
7-10
INDEX
INDEX
Symbols Auto idle stop timer - Set.......................................3-66
Auto switch..........................................................3-206
12H/24H display mode - Switch............................3-75 AUX.....................................................................3-217
3m wide blade - Handle.......................................... 6-7 Avoid mixing oil....................................................... 4-3
A B
Accumulator - Check function............................... 4-67 Backup alarm operation - Check.........................3-146
Accumulator - Function......................................... 4-67 Band/AUX selector button...................................3-216
Accumulator - Handle........................................... 2-34 Basic operation of machine monitor........................3-7
Accumulator for control circuit - Check / Release ni- Battery.................................................................3-229
trogen gas charge pressure...........................4-67 Battery - Check electrolyte level from side............4-46
Accumulator for control circuit - Replace.............. 4-76 Battery - Check electrolyte level impossible from side.
Action level display............................................... 3-15 .......................................................................4-46
Actions if fire occurs.............................................. 2-11 Battery - Handle.................................................... 2-30
Actions when running out of fuel.........................3-234 Battery - Remove / Install....................................3-236
Additional fuel strainer - Check / Clean.................4-48 Battery disconnect switch................................... 3-102
Adjust.................................................................... 4-21 Battery electrolyte - Check level........................... 4-45
After cold weather season.................................. 3-230 Before starting engine - Check / Adjust................ 2-19
After finishing work - Check................................ 3-197 Beware of asbestos dust.......................................2-19
Aftertreatment devices regeneration.....................3-67 Blade - Angle...................................................... 3-191
Aftertreatment devices regeneration disable - Cancel. Blade - Fold.............................................................6-8
..................................................................... 3-113 Blade - Unfold......................................................... 6-9
Aftertreatment devices regeneration disable - Set....... Blade boss - Adjust play....................................... 6-10
..................................................................... 3-110 Blade control lever................................................ 3-87
Aftertreatment devices regeneration disable pilot Blade control lever of power angle power tilt dozer.....
lamp............................................................... 3-31 .......................................................................3-91
Aftertreatment devices regeneration pilot lamp.... 3-31 Blade control lever of SIGMADOZER................... 3-88
Air cleaner - Check / Clean / Replace...................4-15 Blade edge - Adjust angle...................................3-187
Air cleaner clogging caution lamp......................... 3-27 Blade edge of angle dozer - Adjust angle........... 3-187
Air conditioner - Check / Maintenance.................. 4-33 Blade edge of power angle power tilt dozer - Adjust
Air conditioner - Handle...................................... 3-202 angle............................................................ 3-188
Air conditioner - Operate.....................................3-207 Blade edge of sigma dozer - Adjust angle.......... 3-188
Air conditioner - Start automatic operation..........3-208 Blade edge of straight tilt dozer - Adjust angle... 3-187
Air conditioner - Start manual operation............. 3-209 Brace of angle blade - Adjust..............................3-185
Air conditioner - Stop automatic operation..........3-209 Brace when used in standard posture (with blade on
Air conditioner - Stop manual operation..............3-211 level) - Adjust............................................... 3-186
Air conditioner compressor drive belt - Check tension. Brake - Check performance.................................. 4-48
.......................................................................4-33 Brake - Use........................................................... 2-23
Air conditioner fresh/recirc filter - Clean................4-54 Brake on downhill................................................3-182
Air conditioner pilot lamp.......................................3-30 Brake pedal...........................................................3-92
Air conditioner recirculation air filter - Replace..... 4-54 Brake pedal - Check stroke.................................3-139
Air conditioner switch..................................3-42,3-207 Brake system caution lamp...................................3-21
Air conditioner system caution lamp..................... 3-27 Buzzer cancel switch............................................ 3-42
Air suspension seat.............................................3-150
Allowable water depth.........................................3-182 C
Alternator - Check................................................. 4-70
Alternator and air conditioner compressor drive belt - Cab glass - Prohibit modification in any way that will
Replace..........................................................4-30 obstruct view................................................3-183
Always use clean washer fluid................................ 4-2 Calendar - Set.......................................................3-73
Amount of tilt - Adjust..........................................3-190 Camera image brightness - Adjust........................3-71
Angle dozer - Adjust tilt amount.......................... 3-190 Camera image selector switch..............................3-46
Antenna...............................................................3-220 Camera screen - Adjust........................................ 3-70
Appoint leader when working with others............. 2-26 Cap and cover with lock........................................3-97
Armrest - Adjust.................................................. 3-153 Cap with lock - Lock............................................3-199
Ashtray..................................................................3-98 Cap with lock - Open...........................................3-198
8-1
INDEX
Cap with lock - Open / Close.............................. 3-198 DEF level caution lamp......................................... 3-23
Caution lamp list................................................... 3-16 DEF level gauge................................................... 3-39
Center brace - Adjust shims..................................4-39 DEF system caution lamp..................................... 3-24
Center brace - Adjust tension..................... 3-185,4-40 DEF system high temperature stop caution lamp. 3-24
Charge level caution lamp.................................... 3-26 DEF tank - Clean.................................................. 4-79
Chassis - Phenomena and actions..................... 3-240 DEF tank breather element - Replace.................. 4-62
Check............................................................4-15,4-21 DEF tank filler cap - Open / Close...................... 3-201
Check / Repair.................................................... 3-193 DEF tank filler cap cover - Lock.......................... 3-200
Check and maintenance....................................... 6-10 DEF tank filler cap cover - Open / Close.............3-200
Check drained oil and used filter.............................4-2 DEF tank filler port cap - Close........................... 3-201
Check service meter reading.................................. 4-2 DEF tank filler port cap - Open........................... 3-201
Check signs and signalman's signals................... 2-18 DEF tank filler port cover - Open........................ 3-200
Checks after inspection and maintenance.............. 4-3 DEF tank mounting portion - Clean.......................4-79
Checks after stopping engine............................. 3-197 Defined life parts list....................................... 4-76,7-2
Checks and adjustment before starting engine............ Defroster - Operate............................................. 3-213
...............................................................3-132,6-4 Directions of machine........................................... 1-10
Checks before starting.......................................... 2-21 Display................................................................ 3-217
Checks before starting - Perform.......................... 4-41 Display and non-display of ECO guidance - Switch.....
Checks before stopping engine.......................... 3-197 .......................................................................3-62
Chemical hazard................................................... 2-34 Display mode - Set................................................3-71
Cigarette lighter.....................................................3-82 Display monitor................................................... 3-206
Clean with compressed air....................................4-28 Display selector button........................................3-217
Clock - Adjust..............................................3-72,3-220 Display setting - Change.......................................3-58
Cold weather operation.......................................3-229 Display/non-display of ECO gauge and drawbar pull
Cold weather operation information.................... 3-229 gauge - Switch............................................... 3-60
Consumable parts...................................................7-3 Display/non-display of guidance when key is OFF -
Consumable parts list............................................. 7-3 Switch............................................................ 3-62
Contents of safety labels.........................................2-6 Do not drop things inside machine..........................4-2
Control levers and pedals..................................... 3-87 Do not get caught in work equipment................... 2-15
Controls and gauges names................................... 3-4 Door - Prohibit opening while operating machine........
Coolant................................................................3-229 .....................................................................3-183
Coolant - Check level / Add................................ 3-135 Door damper - Replace.........................................4-31
Coolant and water for dilution................................. 4-6 Door hinge - Lubricate.......................................... 4-31
Cooling system - Clean inside.............................. 4-19 Door latch - Check................................................ 4-31
Counter-rotation turn - Operate...........................3-178 Door lock striker - Check.......................................4-31
Cover with lock - Lock.........................................3-200 Door open lock......................................................3-96
Cover with lock - Open........................................3-199 Door pocket...........................................................3-97
Cover with lock - Open / Close........................... 3-199 Door wiper - Replace............................................ 4-33
Current abnormality display switch....................... 3-18 Dozing work........................................................ 3-184
Customize switch.................................................. 3-43 Dust indicator...................................................... 3-104
Cutting edge and end bit - Invert / Replace.......... 4-25 Dust indicator - Check.........................................3-138
Dusty jobsite........................................................... 4-3
D
D65EX-18 Specifications........................................ 5-2
E
D65PX-18 - Specifications................................5-2,5-3 ECO gauge/ drawbar pull gauge...........................3-39
Damper case - Change oil.................................... 4-64 ECO guidance record - Check.............................. 3-56
Damper case - Check oil level / Add oil................ 4-63 Electric wiring - Check........................................ 3-139
Daylight saving time - Set..................................... 3-75 Electrical components - Handle.............................. 4-9
Decelerator pedal..................................................3-95 Electrical system - Act for phenomena............... 3-239
Decelerator pedal - Use...................................... 3-182 Electromagnetic interference................................ 2-15
Declaration of conformity...................................... 1-18 Element - Replace................................................ 4-18
DEF...............................................................3-229,4-6 Emergency exit from operator's cab..................... 2-15
DEF - Check level / Add......................................3-141 End of service life......................................... 2-27,4-80
DEF - Store............................................................. 4-8 Energy saving guidance........................................3-55
DEF filter............................................................. 3-129 Engine - Check low-speed run and acceleration 3-164
DEF filter - Replace...............................................4-73 Engine - Check starting condition and unusual noise..
DEF hose - Replace..............................................4-80 .....................................................................3-164
8-2
INDEX
Engine - Operate / Check after starting.............. 3-164 Fire extinguisher................................................. 3-101

Engine - Operate/Check before starting............. 3-155 Fluorinated greenhouse gases............................. 1-14
Engine - Start............................................3-159,3-239 Frequency - Adjust..............................................3-218
Engine - Start in cold weather.............................3-160 Frequency - Auto-preset..................................... 3-218
Engine - Start in normal weather........................ 3-159 Fresh air filter - Replace........................................4-54
Engine - Start with jumper cables............... 2-20,3-238 Fresh and clean lubricants......................................4-2
Engine - Stop...................................................... 3-167 FRESH/RECIRC air selector switch................... 3-206
Engine - Warm up in cold season....................... 3-166 Front wiper - Replace............................................4-32
Engine - Warm-up operation............................... 3-165 Fuel......................................................................... 4-5
Engine brake - Use............................................. 3-182 Fuel - Check level / Add......................................3-140
Engine compartment - Remove deposit..............3-145 Fuel and lubricants..............................................3-229
Engine coolant temperature caution lamp............ 3-19 Fuel and lubricants to match ambient temperature.4-4
Engine coolant temperature gauge.......................3-35 Fuel consumption gauge.......................................3-39
Engine high-pressure piping clamp - Check for loose- Fuel consumption gauge - Set display..................3-59
ness and hardening of rubber........................4-77 Fuel consumption record - Check......................... 3-56
Engine intake pipe clamps - Check all tightening Fuel control dial.....................................................3-82
points............................................................. 4-61 Fuel filler port cap - Open................................... 3-199
Engine oil pan - Check oil level / Add oil.............3-136 Fuel filter port cap - Close...................................3-199
Engine oil pan - Replace oil and engine oil filter car- Fuel gauge............................................................ 3-37
tridge..............................................................4-49 Fuel level caution lamp......................................... 3-20
Engine oil pressure caution lamp..........................3-26 Fuel main filter cartridge - Replace....................... 4-58
Engine overrun caution lamp................................ 3-26 Fuel prefilter cartridge - Replace...........................4-51
Engine related parts - Act for phenomena.......... 3-241 Fuel spray prevention cap - check for missing and
Engine shutdown secondary switch......................3-86 hardening of rubber....................................... 4-78
Engine stop pilot lamp...........................................3-30 Fuel spray prevention cap - Replace.................... 4-79
Engine system caution lamp................................. 3-25 Fuel system - Bleed air....................................... 3-234
Engine technology to conform exhaust gas emission . Fuel tank - Drain water and sediment................. 3-133
.......................................................................1-13 Fuel tank - Open / Close fuel filler port cap.........3-199
Engine valve clearance - Check / Adjust.............. 4-70 Fuel tank breather - Clean.................................... 4-30
Ensure good visibility............................................ 2-18 Fuel tank breather element - Replace...................4-60
Ensuring safe operation........................................ 2-10 Fuel, coolant and lubricants according to ambient
Equalizer bar center pin - Lubricate...................... 4-44 temperature - Method for using....................... 7-9
Equalizer bar side pin - Lubricate......................... 4-44 Function switches................................................. 3-45
Every 1000 hours maintenance............................ 4-55 Function switches and guidance icons................. 3-40
Every 2000 hours maintenance............................ 4-64 Fuse...................................................................... 3-99
Every 250 hours maintenance.............................. 4-42 Fusible link.......................................................... 3-100
Every 4000 hours maintenance............................ 4-75
Every 4500 hours maintenance............................ 4-79 G
Every 50 hours maintenance................................ 4-41
Every 500 hours maintenance.............................. 4-49 Gauges - Watch.................................................. 3-181
Every 8000 hours maintenance............................ 4-79 Gear - Shift..........................................................3-172
Every 9000 hours maintenance............................ 4-79 Gear shift mode - Change...................................3-173
Explanation of air conditioner equipment............3-203 Gear shift mode - Display................................... 3-173
Explanation of components.............................. 3-6,6-3 Gear shift mode selector switch............................3-45
Explanation of machine monitor equipment............3-6 Gear speed - Change with shift switch during travel....
Explanation of radio equipment.......................... 3-216 .....................................................................3-175
Gear speed - Operate / Preset by shift switch in neu-
tral................................................................3-173
F Gear speed display section...................................3-35
Fan control system caution lamp.......................... 3-25 General character and precautions for handling...2-36
Fan reverse rotation pilot lamp............................. 3-29 General precautions................................................6-2
Fan switch...........................................................3-203 General precautions common to operation and main-
Features of each mode....................................... 3-179 tenance.......................................................... 2-10
Filter........................................................................ 4-8 General view...............................................3-2,6-3,6-7
Fin - Clean by rotating hydraulic drive fan in reverse... GPS synchronization - Set....................................3-73
.......................................................................4-27 Grease.................................................................... 4-7
Final drive case - Change oil................................ 4-57 Grouser - Measure height................................... 3-194
Final drive case - Check oil level / Add oil............ 4-45 Guards.................................................................. 2-27
8-3
INDEX
Guidance display.................................................. 3-32 Komatsu Diesel Particulate Fillter (KDPF) - Handle.....

Guide line display mode - Set............................... 3-72 .....................................................................3-104
Guide to reduce vibration levels on machine.......... 1-8 Komatsu genuine lubricants....................................4-2
Komatsu genuine replacement parts...................... 4-2
H Komatsu machine operator privacy policy.............. 1-3
KOMTRAX.......................................................... 3-129
Handle oil, fuel, coolant, and performing oil clinic...4-5
Handrails and steps - Use.....................................2-13
Hard or frozen ground or ditch - Dig................... 3-185
L
Headlamp switch...................................................3-85 L.H. armrest - Adjust........................................... 3-154
High register range (treble) - Adjust....................3-220 Lamp - Check operation......................................3-144
High-pressure hoses and pipings - Handle...........2-32 Language settings.................................................3-76
High-voltage cables - Caution not go close.......... 2-17 Leveling work...................................................... 3-184
Horn - Check operation.......................................3-145 Lift cylinder head - Adjust shims........................... 4-38
Horn switch........................................................... 3-84 Lifting of personnel prohibited...............................2-14
Hydraulic circuit - Bleed air............................. 4-3,4-35 Link pitch - Measure............................................3-194
Hydraulic circuit - Release internal pressure........ 4-69 Loading and unloading with trailer...................... 3-222
Hydraulic components - Handle..............................4-9 Location of engine serial No. plate........................1-14
Hydraulic fan - Rotate in reverse.......................... 3-63 Location of product identification number (PIN)/
Hydraulic oil temperature caution lamp.................3-20 machine serial number.................................. 1-14
Hydraulic oil temperature gauge........................... 3-37 Location of safety labels......................................... 2-5
Hydraulic ripper - Handle........................................ 6-3 Lock.................................................................... 3-197
Hydraulic tank - Check oil level / Add oil.............3-134 Lock inspection cover............................................. 4-3
Hydraulic tank - Replace oil / Hydraulic oil filter ele- Low register range (bass) - Adjust...................... 3-220
ment - Replace / Hydraulic tank strainer - Clean.. Lubrication chart..................................................... 7-6
.......................................................................4-65 Lumber support - Adjust........................... 3-149,3-151
Hydraulic tank breather - Clean............................ 4-29
Hydraulic tank breather element - Replace...........4-62 M
Machine - Adjust digging depth...............................6-4
I Machine - Adjust tilt amount when angled posture......
Idler - Adjust clearance......................................... 4-24 .....................................................................3-192
Idler - Check oil level.............................................4-23 Machine - Check walk-around...................... 3-132,6-4
If any problem is found..........................................2-11 Machine - Lift...................................................... 3-226
If machine monitor shows warning display......... 3-243 Machine - Load................................................... 3-222
Indicator - Check electrolyte level......................... 4-47 Machine - Lubricate...................................... 4-35,4-42
Inside operator's compartment..............................2-11 Machine - Operate.............................................. 3-192
Inspecting machine............................................... 2-10 Machine - Operate with cold air to face and warm air
Introduction........................................................... 1-10 to feet........................................................... 3-211
Machine - Park....................................................3-195
J Machine - Running-in the new machine..............3-164
Machine - Secure................................................3-223
Jobsite - Investigate/confirm conditions................ 2-17 Machine - Shift gear............................................3-171
Joystick (steering, directional and gear shift lever) Machine - Shift gear in preset mode................... 3-174
(PCCS lever)..................................................3-94 Machine - Start....................................................3-169
Joystick (steering, directional and gear shift lever) Machine - Start (Travel forward and reverse) / Stop....
(PCCS lever) - Adjust.................................. 3-153 .....................................................................3-169
Jumper cable - Connect......................................3-238 Machine - Start after long-term storage.............. 3-232
Jumper cable - Disconnect................................. 3-239 Machine - Steer...................................................3-177
Machine - Stop....................................................3-171
K Machine - Switch travel direction........................ 3-176
Machine - Transport......................................3-221,6-8
KCCV filter element - Replace.............................. 4-70 Machine - Travel on load.....................................3-221
KDPF - Clean........................................................4-79 Machine - Turn during forward travel.................. 3-178
KDPF soot accumulation caution lamp................. 3-23 Machine - Turn gradually during forward travel on
KDPF system caution lamp...................................3-22 downhill slope.............................................. 3-179
Keep machine clean............................................. 2-10 Machine - Turn normally..................................... 3-177
Komatsu Closed Crankcase Ventilation (KCCV).3-114 Machine - Turn on downhill slope....................... 3-179
8-4
INDEX
Machine - Unload................................................3-225 OFF switch..........................................................3-203

Machine equipment name.......................................3-2 Oil............................................................................4-5
Machine monitor - Check.................................... 3-145 Oil cooler fin and air conditioner condenser net -
Machine monitor - Operate when operator identifica- Clean............................................................. 4-29
tion function is available with skip..................3-77 Only authorized personnel.................................... 2-26
Machine monitor - Operate when operator identifica- Operating mode display........................................ 3-30
tion function is available without skip.............3-78 Operating mode selector switch............................3-43
Machine monitor - Operate when starting engine in Operation records - Check....................................3-55
abnormal situation..........................................3-11 Operator ID........................................................... 3-77
Machine monitor - Operate when starting engine in Operator's seat - Adjust...................................... 3-146
normal situation............................................... 3-7 Other equipment................................................... 3-96
Machine monitor - Operate when starting engine Other precautions................................................. 2-36
while engine shutdown secondary switch is ON... Other trouble.................................................3-239,6-6
.........................................................................3-8 Outer element - Clean...........................................4-16
Machine monitor - Operate when starting switch is Outline of gear shift mode...................................3-172
ON while operator ID input is set................... 3-10 Outline of KOMTRAX..........................................3-129
Machine monitor - Operate when stopping engine in Outline of maintenance........................................... 4-5
normal situation............................................... 3-9
Machine monitor - Operate when trouble occurs while P
operating machine......................................... 3-12
Machine monitor equipment name..........................3-5 Parking brake lever............................................... 3-92
Machine operations and controls............3-132,6-4,6-8 Parking brake pilot lamp....................................... 3-32
Machine settings................................................... 3-63 Parking brake system caution lamp...................... 3-24
Main use of machine.............................................1-10 Perform KOWA (Komatsu Oil Wear Analysis)........ 4-7
Maintenance during long-term storage............... 3-232 Periodic replacement of defined life parts.............2-35
Maintenance of air conditioner..............................2-34 Pilot display...........................................................3-29
Maintenance procedure........................................ 4-15 Pilot display and meter display............................. 3-28
Maintenance schedule.......................................... 4-13 Power angle power tilt dozer - Lubricate...............4-41
Maintenance schedule table................................. 4-13 Power button.......................................................3-216
Maintenance screen - Set..................................... 3-67 Power supply outlet...............................................3-98
Maintenance time caution lamp............................ 3-27 Power train case - Check oil level / Add oil.........3-137
Manual stationary regeneration - Operate.......... 3-108 Power train case - Replace oil / Power train pump
Master link connecting bolt - Retighten.................4-23 strainer/Scavenging pump strainer - Clean... 4-55
Mechanical suspension seat...............................3-147 Power train case breather - Clean........................ 4-61
Message - Check.................................................. 3-80 Power train oil filter element - Replace................. 4-53
Message - Reply................................................... 3-80 Power train oil temperature caution lamp............. 3-19
Message display........................................... 3-30,3-79 Power train oil temperature gauge........................3-36
Meter display.........................................................3-35 Precautions after daily work completion in cold
Method for adjusting........................................... 3-146 weather........................................................ 3-230
Method for checking before starting....................3-133 Precautions before starting inspection and mainte-
Mirrors - Adjust....................................................3-152 nance............................................................. 2-26
Monitor settings.....................................................3-69 Precautions before starting operation................... 2-10
Monitor switches................................................... 3-40 Precautions for adding.......................................... 2-36
Multi gauge........................................................... 3-35 Precautions for adding DEF....................................4-2
Multi gauge - Use..................................................3-50 Precautions for blind spots caused by cab and ROPS
Multi gauge selector switch...................................3-49 structures..................................................... 3-184
Precautions for charging battery......................... 3-237
Precautions for check and maintenance...............2-30
N Precautions for cold weather................................ 2-20
No jumping on or off machine............................... 2-14 Precautions for compressed air............................ 2-34
No people on attachments.................................... 2-14 Precautions for DEF..............................................2-36
Noise.......................................................................1-7 Precautions for discharged battery..................... 3-236
Precautions for disposing of waste materials........2-34
O Precautions for fire hazard and leakage............... 2-36
Precautions for floating operation....................... 3-183
Observance of the applicable laws and regulations, Precautions for getting on or off machine............. 2-13
exemption.................................................... 3-130 Precautions for high voltage................................. 2-33
Off season - Check............................................... 4-35 Precautions for high-pressure fuel........................ 2-32
8-5
INDEX
Precautions for high-pressure grease when adjusting Product information...............................................1-14

track tension.................................................. 2-33 Prohibited operations......................................2-23,6-8
Precautions for high-pressure oil.......................... 2-32 Provide fire extinguisher and first aid kit............... 2-11
Precautions for high-temperature coolant.............2-31
Precautions for high-temperature oil.....................2-31 R
Precautions for high-temperature parts................ 2-32
Precautions for installing, removing, or storing attach- R.H. armrest - Adjust.......................................... 3-153
ments............................................................. 2-28 Radiator fin / Oil cooler fin - Clean / Check...........4-27
Precautions for jobsite.......................................... 2-17 Radiator fin and oil cooler fin - Clean....................4-29
Precautions for KDPF............................................. 4-3 Radio - Control....................................................3-218
Precautions for long-term storage.......................3-232 Radio - Handle.................................................... 3-216
Precautions for long-time continuous travel........3-182 Read this manual.................................................... 1-2
Precautions for maintenance.......................... 2-26,4-2 Rear lamp switch.................................................. 3-85
Precautions for noise............................................ 2-33 Rear wiper - Replace............................................ 4-33
Precautions for opening and closing engine side cov- Rearview monitor brightness adjustment switch...3-85
er......................................................................4-3 Recoil spring - Prohibit disassembly..................... 2-33
Precautions for operation............. 2-17,2-21,3-181,6-4 Recommended applications for bulldozer...........3-184
Precautions for refilling oil or fuel............................4-2 Recommended brands and qualities other than ko-
Precautions for safety............................................. 6-2 matsu genuine oils.........................................7-10
Precautions for SCR assembly............................... 4-3 Recommended fuel, coolant, and lubricant.............7-6
Precautions for storing.......................................... 2-36 Recommended mode for each work................... 3-179
Precautions for towing and being towed............... 2-25 Recommended modes table............................... 3-181
Precautions for towing machine..........................3-235 Refrigerant (gas) - Check level............................. 4-34
Precautions for transportation...............................2-24 Replace defined life parts..................................... 4-75
Precautions for using brake................................ 3-183 Reverse slow mode pilot lamp.............................. 3-32
Precautions for using KOMTRAX....................... 3-130 Reverse slow mode switch................................... 3-45
Precautions for welding.........................................2-30 Ripper control lever.........................................3-95,6-3
Precautions for working at high places................. 2-28 Ripper point - Replace............................................ 6-5
Precautions for working under machine or work Room lamp switch.................................................3-85
equipment...................................................... 2-29 ROPS mounting bolt - Check for looseness......... 4-64
Precautions related to attachments and options...2-16
Precautions related to protective structure........... 2-15 S
Precautions to prevent fire.................................... 2-11
Precautions when installing hydraulic hoses.......... 4-3 Safety......................................................................2-2
Precautions when leaving machine...................... 2-14 Safety information................................................... 1-6
Precautions when loading and unloading............. 2-24 Safety labels........................................................... 2-4
Precautions when operating machine...................2-23 Safety rules for transporting machine................. 3-221
Precautions when operating on slope.................3-182 Safety-related equipment......................................2-10
Precautions when operating on snow or frozen surfa- Sash glass intermediate lock................................ 3-97
ces................................................................. 2-23 SCR information....................................................3-67
Precautions when parking machine...................... 2-24 Screen - Adjust..................................................... 3-69
Precautions when running engine inside building.2-16 Seat - Adjust direction...............................3-149,3-151
Precautions when standing up from operator's seat.... Seat - Adjust in fore-and-aft direction....... 3-147,3-150
.......................................................................2-14 Seat - Adjust tilt.........................................3-147,3-150
Precautions when starting engine.........................2-20 Seat - Adjust weight and height................ 3-148,3-150
Precautions when traveling in forward or reverse.2-21 Seat - Heat................................................3-149,3-152
Precautions when traveling on slopes........ 2-23,3-182 Seat - Recline........................................... 3-147,3-150
Precautions when TRAVELLING.......................... 2-22 Seat belt - Fasten................................................3-154
Precautions when using hammer..........................2-31 Seat belt - Fasten / Unfasten.............................. 3-154
Precautions when working on loose ground......... 2-17 Seat belt - Unfasten............................................ 3-155
Precautions when working on machine................ 2-29 Seat belt caution lamp.......................................... 3-28
Preheating pilot lamp............................................ 3-29 Seatbelt - Check................................................. 3-154
Preparation for long-term storage....................... 3-232 Select suitable place for inspection and maintenance.
Preparations for safe operation.............................2-10 .......................................................................2-26
Preset - Call up................................................... 3-219 Serial plate............................................................ 1-17
Preset - Register................................................. 3-219 Service meter / Clock............................................3-38
Preset button.......................................................3-216 Service meter / clock display selector switch........3-49
Prevent fire............................................................2-12 Service meter location.......................................... 1-15
8-6
INDEX
Shim for assembly of work equipment - Adjust...3-186 V

Shims at trunnion - Adjust.....................................4-39
Shovel holder...................................................... 3-101 Vent selector switch - Select............................... 3-204
Sound balance - Adjust.......................................3-219 Vibration levels........................................................1-8
Sound control button...........................................3-217 Visibility from operator's seat................................ 1-10
Specifications..................................................5-2,6-10 Volume control button......................................... 3-216
Stability................................................................. 2-26
Standard tightening torque for bolts and nuts....... 4-11 W
Start engine...........................................................2-19
Starting motor - Check.......................................... 4-76 Warning display.....................................................3-13
Starting switch.......................................................3-82 Warning tag during inspection and maintenance - Dis-
Steering system caution lamp...............................3-21 play................................................................ 2-26
Stop engine before performing inspection and main- Warning tags - Use............................................... 2-19
tenance.......................................................... 2-27 Water pump - Check............................................. 4-76
Store oil and fuel..................................................... 4-8 Water separator - Check / Drain water and sediment..
Sunlight sensor................................................... 3-207 .....................................................................3-134
Switches................................................................3-81 Water separator caution lamp............................... 3-26
System caution lamp.............................................3-20 Wear well-fitting clothes and protective equipment......
System operating lamp....................................... 3-103 .......................................................................2-10
Welding instructions................................................4-2
When required.............................................. 4-15,6-10
T Window washer fluid - Check level / Add..............4-32
Target fuel consumption value displayed in ECO Window washer fluid - select................................ 2-35
gauge - Set.................................................... 3-61 Wiper blade - Replace.......................................... 4-32
Temperature set switch....................................... 3-204 Wiper switch..........................................................3-83
Test / Adjust........................................................ 3-193 Work equipment - Adjust.............................. 3-185,6-4
Tilt brace, tilt cylinder head, and pitch cylinder head - Work equipment - Remove................................. 3-221
Adjust shims.................................................. 4-38 Work equipment link - Adjust and adjusting location....
Time - Set..............................................................3-74 .......................................................................4-37
Tips for longer undercarriage life........................ 3-192 Work equipment link - Adjust shim / Adjust tension.....
Towing and being towed....................................... 2-25 .......................................................................4-36
Track - Decrease tension...................................... 4-22 Work equipment links - Adjust.............................. 4-36
Track - Increase tension........................................4-21 Work equipment lock lever....................................3-93
Track roller - Measure diameter.......................... 3-195 Work equipment lock pilot lamp............................ 3-31
Track shoe bolt - Check looseness / Retighten.....4-22 Work equipment system caution lamp.................. 3-21
Track shoe bolt - Retighten................................... 4-23 Work place - Clean / Tidy......................................2-26
Track tension - Check / Adjust.............................. 4-21
Transmission system caution lamp....................... 3-22 Y
Transportation...............................................3-221,6-8
Trees and stumps - Fell / Remove...................... 3-185 Your machine serial numbers and distributor........1-15
Troubles and actions.....................................3-234,6-6
Trunnion cap - Install.............................................4-35
Tuningtime adjustment button.............................3-216
Turn battery disconnect switch to off position....... 2-30
Two workers for maintenance when engine is running
.......................................................................2-27
U
Unauthorized modification.................................... 2-16
Understanding the machine.................................. 2-10
Universal joint - Lubricate..................................... 4-25
Urea SCR system - Handle.................................3-114
Use proper tools....................................................2-29
User menu............................................................ 3-52
User menu display switch..................................... 3-52
8-7
D65EX-18, D65PX-18, D65WX-18 BULLDOZER
Form No. EENAM03355
©2018 KOMATSU
All Rights Reserved
Printed in Belgium 06-2018

Eenam03355 D65ex PX WX-18 1806

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Operation & EENAM03355

READ THIS MANUAL

KOMATSU MACHINE OPERATOR PRIVACY POLICY

• pictures, videos and sound recordings

• Sound power level emitted by the machine, measured ac-

VIBRATION - OPERATING CONDITION

GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE

• Do not repeatedly handle and lift loads

VISIBILITY FROM OPERATOR'S SEAT

Height to evaluate the proximity visibility

ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS

About Engine Technology

LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-

LOCATION OF ENGINE NUMBER PLATE

FLUORINATED GREENHOUSE GASES

Wide air condensor spec.

SERVICE METER LOCATION

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Declares that this machine:

EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................... 3-6

KOMATSU GENUINE REPLACEMENT PARTS ................................................................................ 4-2

PERIODIC REPLACEMENT OF DEFINED LIFE PARTS.......................................................................... 7-2

PRECAUTIONS FOR TRANSPORTATION............................................................................................. 2-24

LOCATION OF SAFETY LABELS

CONTENTS OF SAFETY LABELS

(2) Caution for safety at rear (09802-B0640)

(3) Caution when leaving the operator's seat (09654-B0641)

(4) Caution for high-temperature coolant and hydraulic oil

(5) Caution for handling accumulator (09659-A057B)

(6) Caution for adjusting track tension (09657-A0881)

(7) Caution for handling cable (09808-A0881)

(8) Stop rotation during inspection and maintenance (09667-

(9) Caution for approaching while moving machine (09806-

(10) Prohibition of start by short-circuiting (09842-A0481)

(11) Caution for handling ROPS/FOPS (09620-A3001, 09620-

(13) Caution for high-temperature parts (6166-15–9990)

(14) Caution for handling DEF (09632-61480)

(15) Caution for using seat belt (09848-A0480)

GENERAL PRECAUTIONS COMMON TO OPERATION

PRECAUTIONS BEFORE STARTING OPERATION

UNDERSTAND THE MACHINE

PREPARATIONS FOR SAFE OPERATION

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

KEEP MACHINE CLEAN

• If water gets into the electrical system, electric devices will

PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

IF ANY PROBLEM IS FOUND

PRECAUTIONS TO PREVENT FIRE

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE

(Power angle power tilt dozer)

• Always face the machine and maintain at least three-point

NO JUMPING ON OR OFF MACHINE

LIFTING OF PERSONNEL PROHIBITED

PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

PRECAUTIONS WHEN LEAVING MACHINE

• When leaving the machine, always lower the work equip-

EMERGENCY EXIT FROM OPERATOR'S CAB

DO NOT GET CAUGHT IN WORK EQUIPMENT

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

As for the machine equipped with ROPS, if the machine weight

• If the machine is equipped with a protective structure, do