TEN00352-00

BULLDOZER D275AX -5E0

SERIAL NUMBERS 30209 and up

WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
NOTICE
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
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BEFORE READING THIS MANUAL FOREWORD

BEFORE READING 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 fundamental 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 precautions.
If you carry out 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. Improper operation and maintenance
of the machine can be hazardous and could result in 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
location shown on the right so that all relevant personnel can read
it at any time.

Location to Keep Operation & Maintenance Manual

In door pocket inside of cab door

If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details
regarding the machine serial No. you will need to provide your Komatsu distributor, see "TABLE TO ENTER SERIAL
NO. AND DISTRIBUTOR (PAGE 1-8)".

This manual uses the international 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. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For 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 Komatsu or your Komatsu
distributor before operating the machine.

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FOREWORD SAFETY INFORMATION

SAFETY INFORMATION
To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.

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 message.

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 exists which, if not avoided,
may result in minor or moderate injury.

The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.

This precaution is given where the machine may be damaged or the service life reduced if
the precaution is not followed.

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

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INTRODUCTION FOREWORD

INTRODUCTION
USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
Dozing
Cutting into hard or frozen ground or ditching
Felling trees, removing stumps
Pushing
Ripping
For further details, see "WORK POSSIBLE USING BULLDOZER (PAGE 3-122)" and "RIPPER OPERATION
(PAGE 3-129)".

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE

(1) Operator's seat (A) Front (C) Left

(2) Sprocket (B) Rear (D) Right

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

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FOREWORD INTRODUCTION

VISIBILITY FROM OPERATOR'S SEAT

The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.

PROXIMITY VISIBILITY
The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown
in the diagram below. The hatched area (A) shows the area where the view is blocked by part of the machine when
mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot be
seen when operating the machine.

12M CIRCUMFERENCE VISIBILITY

The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show
the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be fully
aware that there are places that cannot be seen when operating the machine.

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NECESSARY INFORMATION FOREWORD

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

PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE

Under the front of the console box on the right side of the operator's seat.
The design of the nameplate differs according to the territory.

EPA REGULATIONS, ENGINE NUMBER PLATE

The engine serial number plate is located in the rear portion of the exhaust manifold on the left side of the engine,
as viewed from the cooling fan side.
(The EPA auxiliary plate is on the upper portion of the filter mounting bracket on the inside of the left engine side
cover.)

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

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FOREWORD NECESSARY INFORMATION

BLADE SERIAL NO. PLATE POSITION

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

RIPPER SERIAL NO. PLATE POSITION

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

POSITION OF SERVICE METER

On top of the machine monitor

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NECESSARY INFORMATION FOREWORD

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.

Engine serial No.

Product identification number (PIN)

Distributor name

Address

Service Personnel

Phone/Fax

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FOREWORD CONTENTS

CONTENTS
FOREWORD 1- 1
BEFORE READING THIS MANUAL 1- 2
SAFETY INFORMATION 1- 3
INTRODUCTION 1- 4
USE OF MACHINE 1- 4
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 4
VISIBILITY FROM OPERATOR'S SEAT 1- 5
NECESSARY INFORMATION 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE 1- 6
EPA REGULATIONS, ENGINE NUMBER PLATE 1- 6
BLADE SERIAL NO. PLATE POSITION 1- 7
RIPPER SERIAL NO. PLATE POSITION 1- 7
POSITION OF SERVICE METER 1- 7
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
POSITIONS OF SAFETY PICTOGRAMS 2- 5
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
FIRE PREVENTION 2- 12
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- 15
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 15
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 16
PRECAUTIONS FOR OPERATION 2- 17
PRECAUTIONS FOR JOBSITE 2- 17
STARTING ENGINE 2- 19
OPERATION 2- 22
TRANSPORTATION 2- 26
TOWING 2- 27
PRECAUTIONS FOR MAINTENANCE 2- 28
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 28
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 32
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
FRONT PANEL 3- 5
SWITCHES 3- 36
CONTROL LEVERS, PEDALS 3- 40
DUST INDICATOR 3- 50
POWER SOURCE 3- 50
FUSE BOX 3- 51

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CONTENTS FOREWORD

CAP WITH LOCK 3- 55

DOOR OPEN LOCK 3- 57
SASH GLASS INTERMEDIATE LOCK 3- 58
DOOR POCKET 3- 58
ASHTRAY 3- 58
TOOL BOX 3- 59
CAR STEREO, HANDLING 3- 60
AIR CONDITIONER, HANDLING 3- 68
OPERATION 3- 73
CHECK BEFORE STARTING ENGINE, ADJUST 3- 73
STARTING ENGINE 3- 95
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-100
STOPPING ENGINE 3-103
MOVING MACHINE 3-104
STOPPING MACHINE 3-106
SHIFTING GEAR 3-107
SHIFTING BETWEEN FORWARD AND REVERSE 3-112
STEERING MACHINE 3-114
PRECAUTIONS FOR OPERATION 3-117
PARKING MACHINE 3-119
CHECK AFTER STOPPING ENGINE 3-120
CHECK AFTER FINISHING WORK 3-121
LOCKING 3-121
WORK POSSIBLE USING BULLDOZER 3-122
EFFECTIVE USE OF MODE SELECTION SYSTEM 3-124
RIPPER OPERATION 3-129
OPERATING METHOD FOR RIPPING OPERATIONS 3-132
ADJUSTING POSTURE OF WORK EQUIPMENT 3-137
TIPS FOR LONGER UNDERCARRIAGE LIFE 3-141
TRANSPORTATION 3-143
TRANSPORTATION PROCEDURE 3-143
LOADING, UNLOADING WORK 3-143
METHOD OF LIFTING MACHINE 3-146
TRAVELING ON ROADS 3-147
REMOVAL OF CAB 3-148
INSTALLATION OF CAB 3-148
COLD WEATHER OPERATION 3-149
PRECAUTIONS FOR LOW TEMPERATURE 3-149
AFTER COMPLETION OF WORK 3-151
AFTER COLD WEATHER 3-151
LONG-TERM STORAGE 3-152
BEFORE STORAGE 3-152
DURING STORAGE 3-152
AFTER STORAGE 3-152
STARTING MACHINE AFTER LONG-TERM STORAGE 3-152
TROUBLESHOOTING 3-153
AFTER RUNNING OUT OF FUEL 3-153
METHOD OF TOWING MACHINE 3-154
IF BATTERY IS DISCHARGED 3-155
OTHER TROUBLE 3-159

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FOREWORD CONTENTS

WHEN MODE SELECTION SYSTEM FLASHES 3-164

MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 5
OUTLINE OF ELECTRIC SYSTEM 4- 9
HANDLING HYDRAULIC RELATED EQUIPMENT 4- 10
WEAR PARTS 4- 11
WEAR PARTS LIST 4- 11
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 13
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER
THAN KOMATSU GENUINE OIL 4- 15
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 16
TORQUE LIST 4- 16
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 17
SAFETY CRITICAL PARTS 4- 17
MAINTENANCE SCHEDULE CHART 4- 19
MAINTENANCE SCHEDULE CHART 4- 19
SERVICE PROCEDURE 4- 21
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 21
WHEN REQUIRED 4- 22
CHECK BEFORE STARTING 4- 50
EVERY 250 HOURS SERVICE 4- 51
EVERY 500 HOURS SERVICE 4- 58
EVERY 1000 HOURS SERVICE 4- 64
EVERY 2000 HOURS SERVICE 4- 72
EVERY 4000 HOURS SERVICE 4- 82
EVERY 8000 HOURS SERVICE 4- 86
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAUTIONS 6- 2
PRECAUTIONS RELATED TO SAFETY 6- 2
SELECTION OF TRACK SHOE 6- 3
SELECTION OF TRACK SHOES 6- 3
PROCEDURE FOR SELECTING RIPPER POINT 6- 4
EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER 6- 5
BLADE CONDITION 6- 5
DOZING WORK 6- 7
LEVELING (SPREADING) OPERATION 6- 10
DITCHING OPERATION 6- 10
BOULDER RAISING OPERATION 6- 10
SIDE-CUTTING OPERATIONS 6- 11
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND) 6- 11
SHOE SLIP CONTROL 6- 12
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL) 6- 12
EFFECTIVE USE OF MODE SELECTION SYSTEM 6- 14
IF MODE SELECTION SYSTEM FLASHES 6- 21
HANDLING MACHINES EQUIPPED WITH KOMTRAX 6- 22
BASIC PRECAUTIONS 6- 22

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CONTENTS FOREWORD

INDEX 7- 1

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SAFETY SAFETY

SAFETY
SAFETY LABEL 2- 5
POSITIONS OF SAFETY PICTOGRAMS 2- 5
SAFETY LABELS 2- 6

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 10

PRECAUTIONS BEFORE STARTING OPERATION 2- 10
ENSURING SAFE OPERATION 2- 10
UNDERSTANDING THE MACHINE 2- 10
PREPARATIONS FOR SAFE OPERATION 2- 10
PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 10
INSPECTING MACHINE 2- 10
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2- 10
KEEP MACHINE CLEAN 2- 11
PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT 2- 11
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2- 11
IF ANY PROBLEM IS FOUND 2- 11
FIRE PREVENTION 2- 12
ACTION IF FIRE OCCURS 2- 12
PRECAUTIONS TO 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
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- 14
DO NOT GET CAUGHT IN WORK EQUIPMENT 2- 15
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 15
UNAUTHORIZED MODIFICATION 2- 15
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 15
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 16

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SAFETY SAFETY

PRECAUTIONS FOR OPERATION 2- 17

PRECAUTIONS FOR JOBSITE 2- 17
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 17
WORKING ON LOOSE GROUND 2- 17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 18
ENSURE GOOD VISIBILITY 2- 18
CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 19
BEWARE OF ASBESTOS DUST 2- 19
STARTING ENGINE 2- 19
USE WARNING TAGS 2- 19
INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE 2- 20
PRECAUTIONS WHEN STARTING ENGINE 2- 20
PRECAUTIONS IN COLD AREAS 2- 20
STARTING WITH BOOSTER CABLES 2- 21
OPERATION 2- 22
CHECKS BEFORE OPERATION 2- 22
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 22
PRECAUTIONS WHEN TRAVELING 2- 23
TRAVELING ON SLOPES 2- 23
PRECAUTIONS WHEN OPERATING 2- 25
PROHIBITED OPERATIONS 2- 25
METHOD OF USING BRAKES 2- 25
TRAVELING ON SNOW-COVERED OR FROZEN SURFACES 2- 25
PARKING MACHINE 2- 25
TRANSPORTATION 2- 26
LOADING AND UNLOADING 2- 26
TOWING 2- 27
PRECAUTIONS WHEN TOWING 2- 27

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SAFETY SAFETY

PRECAUTIONS FOR MAINTENANCE 2- 28

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 28
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 28
KEEP WORKPLACE CLEAN AND TIDY 2- 28
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 28
ONLY AUTHORIZED PERSONNE 2- 28
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 28
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 29
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 30
INSTALLING, REMOVING, OR STORING ATTACHMENTS 2- 30
PRECAUTIONS WHEN WORKING AT HIGH PLACES 2- 30
PRECAUTIONS WHEN WORKING ON TOP OF MACHINE 2- 31
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2- 31
PROPER TOOLS 2- 31
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 32
PRECAUTIONS WHEN WELDING 2- 32
HANDLING BATTERY 2- 32
PRECAUTIONS WHEN USING HAMMER 2- 33
PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT 2- 33
PRECAUTIONS WITH HIGH-TEMPERATURE OIL 2- 33
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 34
PRECAUTIONS WITH HIGH-PRESSURE FUEL 2- 34
HANDLING HIGH-PRESSURE HOSES AND PIPING 2- 34
NOISE 2- 34
PRECAUTIONS WITH HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION 2- 35
DO NOT DISASSEMBLE RECOIL SPRING 2- 35
HANDLING ACCUMULATOR AND GAS SPRING 2- 36
PRECAUTIONS WITH COMPRESSED AIR 2- 36
MAINTENANCE OF AIR CONDITIONER 2- 36
DISPOSING OF WASTE MATERIALS 2- 36
METHOD OF SELECTING WINDOW WASHER FLUID 2- 36
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 37

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SAFETY SAFETY LABELS

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

POSITIONS OF SAFETY PICTOGRAMS

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SAFETY LABELS SAFETY

SAFETY LABELS
(1) Caution before operating or maintaining machine
(09651-03001)

(2) Caution before moving in reverse (09802-13000)

(3) Caution for leaving operator's seat (09654-33001)

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SAFETY SAFETY LABELS

(4) Caution for high-temperature coolant (09668-03001)

(5) Caution for high-temperature hydraulic oil (09653-03001)

(6) Caution for check and adjust track tension (195-98-22931)

(7) Caution for handling electric wires (09808-03000)

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SAFETY LABELS SAFETY

(8) Caution for engine running (09667-03001)

(9) Caution for handling accumulator (09659-53000)

(10) Caution for use of seat belt (195-98-12940)

(11) Caution for approach when machine moving (09812-03000)

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SAFETY SAFETY LABELS

(12) Warning for ROPS (09620-30201)

(13) Warning for battery (09664-30082)

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GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY

GENERAL PRECAUTIONS COMMON TO OPERATION AND

MAINTENANCE
Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying
out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully
and obey the warnings.

PRECAUTIONS BEFORE STARTING OPERATION

ENSURING 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 carrying out the operation.

UNDERSTANDING THE MACHINE

Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.

PREPARATIONS FOR SAFE OPERATION

PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT

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

INSPECTING MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

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

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SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

KEEP MACHINE CLEAN

If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or
oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machine
clean.
If water gets into the electrical system, there is a hazard that it
will cause malfunctions or misoperation. If there is any
misoperation, there is danger that the machine 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 components.

PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT

When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.
If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
Do not leave tools or a 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 cell phone when driving or operating the machine. This may lead to mistakes in operation, which
could 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

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

IF ANY PROBLEM IS FOUND

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

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GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY

FIRE PREVENTION

ACTION IF FIRE OCCURS

Turn the start switch OFF to stop the engine.
Use the handrails and steps to get off the machine.
Do not jump off the machine. There is the danger of falling and suffering serious injury.

PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, antifreeze, or window washer fluid
Do not bring any flame or fire close to flammable substances
such as fuel, oil, antifreeze, or window washer fluid. There is
danger that they may catch fire. To prevent fire, always observe
the following:
Do not smoke or use any flame near fuel or other flammable
substances.
Stop the engine before adding fuel.
Do not leave the machine when adding fuel or oil.
Tighten all 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 flammable 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 oil 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 flammable liquids.
Determine well-ventilated areas for storing oil and fuel. Keep
the oil and fuel in the determined place and do not allow
unauthorized persons to enter.
When carrying out grinding or welding work on the machine,
move any flammable materials to a safe place before
starting.

Fire caused by accumulation of flammable material.

Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
To prevent fires spreading from sparks or burning particles from other fires, remove any flammable materials
such as dry leaves, chips, pieces of paper, coal dust, or any other flammable 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. To prevent fire, always observe the following.
Keep all electric wiring connections clean and securely tightened.
Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair
or replace any damaged wiring.

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SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

Fire coming 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, serious personal injury or death.

Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications.
When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.

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 do as follows.
Use the parts marked by arrow A in the diagrams when getting
on or off the machine.
Never use the parts marked by arrow B when getting on or off
the machine. Use them only when moving along the top of the
track or when checking or carrying out maintenance inside the
side cover, or when filling the tank with oil.

Always face the machine and maintain at least three-point

contact (both feet and one hand, or both hands and one foot)
with the handrail and steps to ensure that you support yourself.

Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on
them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts.
Do not grip the control levers and work equipment lock lever when getting on or off the machine.
Never climb on the engine hood or covers where there are no non-slip pads.
Do not get on or off the machine while holding tools in your hand.

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GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY

NO JUMPING ON OR OFF MACHINE

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

NO PEOPLE ON ATTACHMENTS
Never let anyone ride on the work equipment or other attachments. There is a hazard of falling and suffering serious
personal injury or death.

PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

When standing up from the operator's seat to adjust the operator's
seat, always lower the work equipment completely to the ground,
set work equipment lock lever (1) and parking brake lever (2) to the
LOCK position (L), and stop the engine.
If the control lever is touched by accident, there is danger that the
machine may suddenly move and cause serious personal injury.

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 do the following.
When leaving the machine, always lower the work equipment
completely to the ground, set work equipment lock lever (1) and
parking brake lever (2) to the LOCK position (L), and stop the
engine.
Always lock all parts, take the key with you and leave it in the
specified place.

EMERGENCY EXIT FROM OPERATOR'S CAB

Machines equipped with a cab have doors on the left and right sides. If the door on the one side does not open,
escape from the door on the other side.

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SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

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 get
caught, you may suffer serious personal injury or death. Do not allow anyone to come close to any rotating or
extending/retracting portion.

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

The operator's compartment is equipped with a structure (ROPS,
FOPS) to protect the operator by absorbing the impact energy. If
the machine weight (mass) exceeds the certified value (shown on
the ROLL-OVER PROTECTIVE STRUCTURE (ROPS)
CERTIFICATION plate), ROPS will not be able to fulfill its function.
Do not increase machine weight beyond the certified value by
modifying the machine 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 or death. Always observe the
following.
If the machine is equipped with a protective structure, do not
remove the protective structure and carry out 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. Consult
your Komatsu distributor before carrying out any modifications.
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 contact your Komatsu distributor for
advice on the method of repair.
Even if the protective structure is installed, always fasten your seat belt properly when operating the machine.
If you do not fasten your seatbelt properly, it cannot display its effect.

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

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

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

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GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY

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 machine
must be operated inside a building or under ground, where the
ventilation is poor, take steps to ensure that the engine exhaust
gas is removed and that ample fresh air is brought in.

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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 personal injury or death. Before starting
operations, always check the following to confirm that there is no danger on the jobsite.
When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there
is a hazard of fire, so be careful when operating.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not operate where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or damage any of these lines.
Take necessary measures to prevent any unauthorized person
from entering the operating area.
In particular, if you need to operate on a road, protect pedestrian
and cars by designating a person for worksite traffic duty or by
installing fences around the worksite.
When traveling or operating in water or on soft ground, check
the water depth, speed of the current, bedrock, and shape of the
ground beforehand and avoid any place that will obstruct travel.

WORKING ON LOOSE GROUND

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

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PRECAUTIONS FOR OPERATION SAFETY

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 do as follows.
Before starting work near electric cables, inform the local power
company of the work to be performed, and ask them to take the
necessary action.

Even going close to high-voltage cables can cause electric

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

ENSURE GOOD VISIBILITY

This machine is equipped with mirrors to ensure good visibility, but even then there are places that cannot be seen
from the operator's seat, so be careful when operating.
When traveling or carrying out operations in places with poor visibility, it is impossible to check for obstacles in the
area around the machine and to check the condition of the jobsite. This leads to danger of serious personal injury
or death. When traveling or carrying out operations in places with poor visibility, always observe the following.
Position a signalman if there are areas where the visibility is not good.
Only one signalman should give signals.
When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
When checking the mirrors installed to the machine, remove all dirt and adjust the angle of the mirror to ensure
good visibility.
If the machine is equipped with cameras, clean off any dirt from the lens and make sure that the camera gives
a clear view.

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SAFETY PRECAUTIONS FOR OPERATION

CHECKING SIGNS AND SIGNALMAN'S SIGNALS

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

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 jobsites handling demolition work or work handling industrial waste. 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.
Do not allow other persons to approach during the operation.
Always observe the rules and regulations for the work site and
environmental standards.
This machine does not use asbestos, but there is a danger that
imitation parts may contain asbestos, so always use genuine
Komatsu parts.

STARTING ENGINE

USE WARNING TAGS

If there is any "DANGER! Do NOT operate!" warning tag displayed,
it means that someone is carrying out inspection and maintenance
of the machine. If the warning sign is ignored and the machine is
operated, there is danger that the person carrying out inspection or
maintenance may be caught in the rotating parts or moving parts
and suffer serious personal injury or death. Do not start the engine
or touch the levers.

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PRECAUTIONS FOR OPERATION SAFETY

INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE

Carry out 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 this inspection is not carried out properly problems may occur with
the operation of the machine, and there is danger that this may lead to serious personal injury or death.
Remove all dirt from the surface of the window glass to ensure a good view.
Carry out the "WALK-AROUND CHECK (PAGE 3-73)".
Remove all dirt from the surface of the lens of the front lamps and working lamps, and check that they light up
correctly.
Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check
for damage to the electric wiring.
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 where it is easy to carry out operations, and check that there is no damage
or wear to the seat belt or mounting clamps.
Check that the gauges work properly, check the angle of the mirror, and check that the control levers are all at
the Neutral position.
Before starting the engine, check that work equipment lock lever
(1) and parking brake lever (2) are in LOCK position (L).
Adjust the mirrors so that you can get a good rear-view from the
operator's seat.
For the details of adjustment, see "ADJUST MIRROR (PAGE
3-90)".
If the machine is equipped with cameras, adjust the angle so
that the surrounding area can be seen clearly from the
operator's seat.
Check that there are no persons or obstacles above, below, or
in the area around the machine.

PRECAUTIONS WHEN STARTING ENGINE

Start and operate the machine only while seated.
When starting the engine, sound the horn as a warning.
Do not allow anyone apart from the operator to ride 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.

PRECAUTIONS IN COLD AREAS

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

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SAFETY PRECAUTIONS FOR OPERATION

STARTING WITH BOOSTER CABLES

If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
Always wear safety goggles and rubber gloves when starting
the engine with booster cable.
When connecting a normal machine to a problem machine with
booster cables, always use a normal machine with the same
battery voltage as the problem machine.
When starting with a booster cable, carry out the starting
operation with two workers (one worker sitting in the operator's
seat and the other working with the battery).
When starting from another machine, do not allow the two
machines to touch.
When connecting the booster cables, turn the starting switch to
the OFF position for both the normal machine and problem
machine. There is a hazard that the machine will move when the
power is connected.
Be sure to connect the positive (+) cable first when installing the
booster cables. Disconnect the negative (-) cable (ground side)
first when removing them.
When removing the booster cables, be careful not to let the
booster cable clips touch each other or to let the clips touch the
machine.
For details of the procedure when starting the machine using a
booster cable, see "STARTING ENGINE WITH BOOSTER
CABLE (PAGE 3-156)".

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PRECAUTIONS FOR OPERATION SAFETY

OPERATION

CHECKS BEFORE OPERATION

If the checks before starting are not carried out properly, the machine will be unable to display its full performance,
and there is also danger that it may lead to serious personal injury or death.
When carrying out the checks, move the machine to a wide area where there are no obstructions, and pay careful
attention to the surrounding area. Do not allow anyone near the machine.
Always wear the seatbelt. There is danger that you may be
thrown out of the operator's seat and suffer serious injury when
the brakes are applied suddenly.
Check the operation of travel, steering and brake systems, and
work equipment control system.
Check for any problem in the sound of the machine, vibration,
heat, smell, or gauges; check also that there is no leakage of oil
or fuel.
If any problem is found, carry out repairs immediately.

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

Lock the cab door and windows securely, both when they are open and when they are closed.
Do not allow anyone apart from the operator to ride on the machine.
If there are any persons in the area around the machine, there
is danger that they may be hit or caught by the machine, and this
may lead to serious personal injury or death. Always observe
the following before traveling.
Always operate the machine only when seated.
Before moving off, check again that there is no person or
obstruction 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 to the rear of the machine which cannot be
seen, position a signalman.
Always be sure to carry out the above precautions even when the
machine is equipped with mirrors and cameras.

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SAFETY PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN TRAVELING

Never turn the starting switch key to the OFF position when the machine is traveling. If the engine stops when
the machine is traveling, it may become impossible to operate the steering, and this may cause serious personal
injury or death. If the engine stops, depress the brake pedal immediately to stop the machine.
When traveling or carrying out operations, always keep a safe distance from people, structures, or other
machines to avoid coming into contact with them.
When traveling on the level ground, keep the work equipment
approximately 40 to 50 cm above the ground. Otherwise, the
work equipment may contact to the ground and the machine
may be turned over.

Avoid traveling over obstacles when possible. If the machine

has to travel over an obstacle, keep the work equipment close
to the ground and travel at low speed. There is more danger of
the machine tipping over to the left or right than tipping over to
the front or rear, so do not travel over obstacles which make the
machine tilt strongly to the left or right sides.
When traveling on rough ground, travel at low speed and do not
operate the steering suddenly. There is danger that the machine
may turn over. The work equipment may hit the ground surface
and cause the machine to lose its balance, or may damage the
machine or structures in the area.
When passing over bridges or structures, check first that the structure is strong enough to support the weight of
the machine. When traveling on public roads, check first with the relevant authorities and follow their instructions.
When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, operate
slowly and be extremely careful not to let the machine body or work equipment hit anything.

TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always do as follows.

2 - 23
.

PRECAUTIONS FOR OPERATION SAFETY

Keep the work equipment approx. 20 to 30 cm (8 to 12 in) above

the ground. In case of emergency, lower the work equipment to
the ground immediately to help stop the machine.
Always travel straight up or down a slope. Traveling at an angle
or across the slope is extremely dangerous.
Do not turn on slopes or travel across slopes. Always go down
to a flat place to change the position of the machine, then travel
on to the slope again.
Travel on grass, fallen leaves, or wet steel plates with low
speed. Even with slight slopes there is a hazard that the
machine may slip.
When traveling downhill, never shift gear or place the
transmission at neutral. It is dangerous not to use the braking
force of the engine. Always place the transmission in a low gear
before starting to travel downhill.
Depress the brake or use the braking effect of the engine as
necessary.

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SAFETY PRECAUTIONS FOR OPERATION

PRECAUTIONS WHEN OPERATING

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
To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with
the sprocket at the rear when carrying out operations.
When using the machine, to prevent personal injury caused by damage to the work equipment or by the machine
overturning due to overloading, do not exceed the permitted performance of the machine or the maximum
permitted load for the structure of the machine.

METHOD OF USING BRAKES

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

TRAVELING ON SNOW-COVERED OR FROZEN SURFACES

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

PARKING MACHINE
Park the machine on firm, level ground.
Select a place where there is no hazard of landslides, falling rocks, or flooding.
Lower the work equipment completely to the ground.
When leaving the machine, set work equipment lock lever (1) to
the LOCK position and parking brake lever (2) to the LOCK
position (L), and stop the engine.
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 leave it in the specified place.

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PRECAUTIONS FOR OPERATION SAFETY

If it is necessary to park the machine on a slope, always do as

follows.
Set the work equipment on the downhill side and dig it into the
ground.
In addition, put blocks under the tracks to prevent the
machine from moving.

TRANSPORTATION
When the machine is transported on a trailer, there is danger of serious personal injury or death during
transportation. Always do as follows.
Always check the machine dimensions carefully. Depending on the work equipment installed, the machine
weight, transportation height, and overall length may 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.
The machine can be divided into parts for transportation, so when transporting the machine, please contact your
Komatsu distributor to have the work carried out.

LOADING AND UNLOADING

When loading or unloading the machine, mistaken operation may
bring the hazard of the machine tipping over or falling, so particular
care is necessary. Always do as follows.
Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of the road or cliff.
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.
Be sure the ramp surface is clean and free of grease, oil, ice and
loose materials. Remove dirt from machine-tracks. On a rainy
(1)Blocks
day, in particular, be extremely careful since the ramp surface is (2)Ramp
slippery. (3)Centerline of trailer
Run the engine at low idling and drive the machine slowly at low (4)Angle of ramps: Max. 15°
speed.
When on the ramps, do not operate any lever except for the
travel lever.
Never correct your steering on the ramps. If necessary, drive off the ramps, correct the direction, then enter the
ramps again.
The center of gravity of the machine will change suddenly at the joint between the ramps and the track or trailer,
and there is danger of the machine losing its balance. Travel 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 boarding the machine. If this is not done, the door
may suddenly open during transportation.
Refer to "TRANSPORTATION (PAGE 3-143)".

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SAFETY PRECAUTIONS FOR OPERATION

TOWING

PRECAUTIONS WHEN TOWING

Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or towing
bar or in the method of towing a disabled machine may lead to serious personal injury or death.
For towing, see "METHOD OF TOWING MACHINE (PAGE 3-154)".
Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine
being towed.
Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope may
break during the towing operation.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing
machine and the machine being towed.

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PRECAUTIONS FOR MAINTENANCE SAFETY

PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE

DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE

Always display the "DANGER! Do NOT operate" warning tag
during the inspection and maintenance. If there is any "DANGER!
Do NOT operate!" warning tag displayed, it means that someone
is carrying out inspection and maintenance of the machine. If the
warning sign is ignored and the machine is operated, there is
danger that the person carrying out inspection or maintenance
may be caught in the rotating parts or moving parts and suffer
serious personal injury or death. Do not start the engine or touch
the levers.
If necessary, put up signs around the machine also.
Warning tag part number: 09963-03001
When not using this warning tag, keep it in the toolbox.
If there is no toolbox, keep it in the pocket for the Operation and
Maintenance Manual

KEEP WORKPLACE CLEAN AND TIDY

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

SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE

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

ONLY AUTHORIZED PERSONNEL

Do not allow any unauthorized personnel into the area when servicing the machine. 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
instructions during the operation.

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SAFETY PRECAUTIONS FOR MAINTENANCE

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

Lower the work equipment completely to the ground and stop
the engine before performing any inspection and maintenance.

Turn the starting switch to the ON position, operate the work

equipment control lever to the RAISE and LOWER position 2 or
3 times repeatedly to release the remaining pressure in the
hydraulic circuit, then set parking brake lever (1) and work
equipment lock lever (2) to the LOCK position (L).
Check that the battery relay is off and main power is not
conducted. (Wait for approx. one minute after turning off the
engine starting switch key and press the horn switch. If the horn
does not sound, it is not activated.)

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

2 - 29
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PRECAUTIONS FOR MAINTENANCE SAFETY

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried
out with the engine running, carry out the operation with at least two workers and do as follows.
One worker must always sit in the operator's seat and be ready
to stop the engine at any time. All workers must maintain
contact with the other workers.
When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts, so
be careful not to come close.
Never drop or insert tools or other objects into the fan, fan belt,
or other rotating parts. There is danger that they may contact
the rotating parts and break or be sent flying.

Set work equipment lock lever (1) and parking brake lever (2) to
the LOCK position (L) to prevent the work equipment from
moving.
Do not touch any control levers. If any control lever must be
operated, give a signal to the other workers to warn them to
move to a safe place.

INSTALLING, REMOVING, OR STORING ATTACHMENTS

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

PRECAUTIONS WHEN WORKING AT HIGH PLACES

When working at high places, use a step ladder or other stand to ensure that the work can be carried out safely.

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SAFETY PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WHEN WORKING ON TOP OF MACHINE

Clean up the machine to prevent falling off when performing
maintenance, always do as follows.
Do not spill oil or grease.
Do not scatter the tools.
Be careful at the time of the walk on the step.
Remove mud and the oils and fats kind of the bottom of
shoes.
Never jump off the machine. When getting on or off the machine,
maintain at least three-point contact (both feet and one hand, or
both hands and one foot) with the handrail and steps to ensure
that you support yourself.
To prevent personal injury caused by slipping or falling off the machine, never climb on the engine hood or covers
except the check passage with non-slip pads.

PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT

Make sure the hoists or jacks you use are in good repair and
strong enough to handle the weight of the component. Never
use jacks at places where the machine is damaged, bent, or
twisted. Never use frayed, twisted or pinched wire rope. 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 control levers is
touched by accident, or there is damage occurring to the
hydraulic piping, the work equipment or the machine will
suddenly drop. This is extremely dangerous. Never work under
the work equipment or the machine.
If it is necessary to raise the work equipment or the machine and then go under it to carry out inspection or
maintenance, 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, there is a hazard that they may come down and that this
may lead to serious personal injury or death.
Never use concrete blocks for supports. They can collapse under even light loads.

PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, deformed, or low quality tools, or
making improper use of the tools may cause serious personal
injury.

2 - 31
.

PRECAUTIONS FOR MAINTENANCE SAFETY

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

PRECAUTIONS WHEN WELDING

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

HANDLING BATTERY
Before inspecting or handling the battery, turn the key in the starting switch to the OFF position.

Danger of battery exploding

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, so always
observe the following.
Do not use or charge the battery if the battery electrolyte is
below the LOWER LEVEL mark. This will cause explosion.
Always carry out periodic inspection of the battery electrolyte
level, and add distilled water (or commercially available
battery filler solution) to the UPPER LEVEL mark.
Do not smoke or bring any 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 carry
out 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, so always
observe the following.
When handling the battery, always wear protective goggles
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.
If battery electrolyte gets on your clothes or skin, wash it off
immediately with large amounts of water.

Removing battery cables

Before repairing the electrical system or carrying out electric welding, turn the starting switch OFF. Wait for
approx. 1 minute, then remove the negative (-) battery cable to stop the flow of electricity.

2 - 32
.

SAFETY PRECAUTIONS FOR MAINTENANCE

Danger of sparks
There is hazard that sparks will be generated, so 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, remove the ground cable (negative (-) cable) first. When installing,
connect 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 fly out or metal particles may be
scattered. This may lead to serious personal injury or death.
Always do as follows.
When hitting pins or bucket teeth, there is a hazard that broken
pieces might be sent flying and injure 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, there is a hazard that pieces
might be scattered and cause serious personal injury or death.
Always wear safety glasses and gloves.
If the pin is hit with strong force, there is a hazard that it may fly
out and injure people in the surrounding area. Do not allow
anyone to enter the surrounding area.

PRECAUTIONS WITH 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 inside the
radiator, and remove the cap.

PRECAUTIONS WITH 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 - 33
.

PRECAUTIONS FOR MAINTENANCE SAFETY

PRECAUTIONS WITH HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. In addition, the fuel piping is also under internal pressure
when the engine is running and immediately after the engine is stopped. When carrying out inspection or
replacement of the piping or hoses, check that the internal pressure in the circuit has been released. If this is not
done, it may lead to serious personal injury or death. Always do as follows.
Do not carry out inspection or replacement when the circuit is still under pressure.
Release the pressure in the hydraulic circuit. For details, see "METHOD OF RELEASING PRESSURE IN
HYDRAULIC CIRCUIT (PAGE 4-81)".
If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping
and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
There is a hazard that high-pressure oil leaking from small holes
may penetrate your skin or cause loss of sight if it contacts your
skin or eyes directly. If you are hit by a jet of high-pressure oil
and suffer injury to your skin or eyes, wash the place with clean
water, and consult a doctor immediately for medical attention.

PRECAUTIONS WITH HIGH-PRESSURE FUEL

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

HANDLING HIGH-PRESSURE HOSES AND PIPING

If oil or fuel leaks from high-pressure hoses or piping, it may cause fire or misoperation, and lead to 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, please 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.

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

2 - 34
.

SAFETY PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WITH HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION

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

DO NOT DISASSEMBLE RECOIL SPRING

Never disassemble the recoil spring assembly. 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.
It is necessary to disassemble the recoil spring assembly, always
ask your Komatsu distributor to carry out the operation.

2 - 35
.

PRECAUTIONS FOR MAINTENANCE SAFETY

HANDLING ACCUMULATOR AND GAS SPRING

This machine is equipped with an accumulator. Even after the engine stops, if the work equipment control lever is
operated soon after stop of the engine in the direction to lower the work equipment, the work equipment goes down
under its own weight.
After stopping the engine, set the parking brake lever and the work equipment lock lever to the LOCK position.
The accumulator and gas spring are charged with high-pressure nitrogen gas. If the accumulator is handled
mistakenly, it may cause an explosion that could lead to serious personal injury or death. For this reason, always
observe the following precautions.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it, weld it, or use a cutting torch.
Do not hit or roll the accumulator, or subject it to any impact.
When disposing of the accumulator, the gas must be released.
Please contact your Komatsu distributor to have this work
performed.

PRECAUTIONS WITH COMPRESSED AIR

When carrying out cleaning with compressed air, there is a hazard of serious personal injury caused by flying dust
or particles.
When using compressed air to clean the filter element or radiator, wear safety glasses, 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.

DISPOSING OF WASTE MATERIALS

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

METHOD OF 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.

2 - 36
.

SAFETY PRECAUTIONS FOR MAINTENANCE

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To enable this machine to be used safely for a long period, always carry out periodic replacement of safety critical
parts that have a particularly close relation to safety, such as hoses and the seatbelt.
For details of the replacement of safety critical parts, see "PERIODIC REPLACEMENT OF SAFETY CRITICAL
PARTS (PAGE 4-17)".
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 safety-critical parts if any defect is found, even when they have not reached the specified
replacement time.

2 - 37
.
.

3-1
.

GENERAL VIEW OPERATION

GENERAL VIEW
GENERAL VIEW OF MACHINE

(1) Blade (6) Sprocket

(2) Blade lift cylinder (7) Track frame
(3) Cab (8) Frame
(4) ROPS (9) Track shoe
(5) Ripper

3-2
.

OPERATION GENERAL VIEW

GENERAL VIEW OF CONTROLS AND GAUGES

(1) Parking brake lever (13) Pivot turn switch

(2) Work equipment lock lever (14) Starting switch
(3) Cigarette lighter (15) Information switch
(4) Fuel control dial (16) Buzzer cancel switch
(5) Joystick (Steering,directional and gear shift lever) (17) Brake pedal
(6) Additional heater switch(if equipped) (18) Deceleration pedal
(7) Front lamp,working lamp switch (19) Blade control lever
(8) Rear lamp switch (20) Horn switch
(9) Air conditioner panel or heater panel (21) Ripper control lever
(10) Display panel A (22) Pin puller control switch (if equipped)
(speed range display,engene speed) (23) Wiper switch
(11) Auto shift down switch (24) Room lamp switch
(12) Fan rotation selector switch

3-3
.

GENERAL VIEW OPERATION

FRONT PANEL

(1) Engine coolant temperature gauge (13) Maintenance caution lamp

(2) Power train oil temperature gauge (14) Warning lamp
(3) Hydraulic oil temperature gauge (15) Fan reversal lamp
(4) Fuel level gauge (16) Display panel A (Speed range, Engine speed)
(5) Radiator coolant level caution lamp (17) Display panel B (Multi-information)
(6) Charge condition caution monitor (18) Dual/single tilt selector display lamp
(7) Engine oil pressure caution lamp (19) Lock up mode switch
(8) Engine coolant temperature caution lamp (20) Economy mode switch
(9) Power train oil temperature caution lamp (21) Reverse slow mode selector switch
(10) Hydraulic oil temperature caution lamp (22) Fan rotation selection impossibility lamp
(11) HSS charge pressure caution lamp (23) Air cleaner clogging caution lamp
(12) Engine pre-heating pilot lamp (24) Torque converter lock up pilot indicator

3-4
.

OPERATION EXPLANATION OF COMPONENTS

EXPLANATION OF COMPONENTS
The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.

FRONT PANEL

(A) Check monitor group (E) Mode selection switch group

(B) Caution monitor group (F) Switches
(C) Emergency caution items (G) Lamps
(D) Meter and indicator group

3-5
.

EXPLANATION OF COMPONENTS OPERATION

A: Check monitor group (for details, see "CHECK MONITOR GROUP (PAGE 3-7)")
Before the engine is started, the basic items among the check before starting items that must be checked are
displayed.
If there is any abnormality, the caution lamp for the location of the abnormality flashes.

NOTICE
When carrying out checks before starting, do not simply rely on the monitor. Always refer to the periodic maintenance items or
"OPERATION (PAGE 3-73)" to carry out the checks.

B: Caution monitor group (See "CAUTION MONITOR GROUP (PAGE 3-9)")

CAUTION
If the caution lamp for any of these items flashes, check and repair the appropriate item as soon as possible.

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

C: Emergency caution items (for details, see "EMERGENCY CAUTION ITEMS (PAGE 3-11)")

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

This displays the abnormal items that action must be taken on immediately the engine is running.
If there is any abnormality, the monitor showing the location of the abnormality will flash and the alarm buzzer will
sound.

D: Meter and indicator display portion (see METER GROUP (PAGE 3-14))
This consists of the preheating pilot lamp, power train oil temperature gauge, engine water temperature gauge,
hydraulic oil temperature gauge. fuel gauge, dual/single selector display lamp, torque converter lock-up display
lamp, display panel A (speed range display, engine speed) and display panel B (multi-information).

E: Mode selection switch group (see "MODE SELECTION SWITCH GROUP (PAGE 3-19)")
This consists of the lock-up mode switch, economy mode selector switch, shoe slip control switch, rockbed selection
mode selector switch, and slow reverse mode selector switch.

F. Switches (see "SWITCHES (PAGE 3-21)")

This consists of the starting switch, buzzer cancel switch, front lamp/working lamp switch, rear lamp switch, auto
shift down switch, fan
rotation selector switch, pivot turn switch, information switch, and additional heater switch (option).

G. Lamps (see "LAMPS (PAGE 3-25)".)

This consists of the warning lamp, and fan operation confirmation lamp.

3-6
.

OPERATION EXPLANATION OF COMPONENTS

CHECK MONITOR GROUP

NOTICE
When performing the check before starting, do not rely only on these monitors. Always refer to "OPERATION (PAGE 3-73)" to
perform these checks.
Park the machine on level ground and then check the monitor lamps.
Confirm that monitor lamps light up about 3 seconds after the starting switch is turned to the ON position. If any monitor lamp
does not light, contact your Komatsu distributor to inspect and repair.

REMARK
When the starting switch is turned to the ON position, before starting the engine, the caution lamps flash for 3
seconds, the warning lamps light up for 3 seconds, and the alarm buzzer sounds for 1 seconds.
The caution lamps cannot be checked for any malfunction until at least 5 seconds after the engine has been
stopped.

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

(1) Radiator coolant level caution lamp

3-7
.

EXPLANATION OF COMPONENTS OPERATION

RADIATOR COOLANT LEVEL CAUTION LAMP

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

3-8
.

OPERATION EXPLANATION OF COMPONENTS

CAUTION MONITOR GROUP

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

NOTICE
Park the machine on level ground and check the monitor lamps.
Confirm that monitor lamps light up about 3 seconds after the starting switch is turned to the ON position. If any monitor lamp
does not light, contact your Komatsu distributor to inspect and repair.

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

(1) Charge condition caution lamp (3) Air cleaner clogging caution lamp
(2) Maintenance caution lamp

3-9
.

EXPLANATION OF COMPONENTS OPERATION

CHARGE CONDITION CAUTION LAMP

Lamp (1) indicates an abnormality in the charging system while the
engine is running.
If the monitor lamp flashes, check the V-belt tension. If any
abnormality is found, see "OTHER TROUBLE (PAGE 3-159)".

REMARK
This monitor lamp lights when the starting switch is turned to ON immediately after the engine is started or
immediately before the engine is stopped. It does not indicate a problem.

MAINTENANCE CAUTION LAMP

Lamp (2) lights up when the filter or oil change interval has been
reached. DISPLAY PANEL B (Multi-information) (PAGE 3-18) to
the maintenance mode and check or replace the applicable filter or
oil.

AIR CLEANER CLOGGING CAUTION LAMP

Lamp (3) warns operator that the air cleaner is clogged.
If it flashes, stop the engine, check and clean the air cleaner.

3 - 10
.

OPERATION EXPLANATION OF COMPONENTS

EMERGENCY CAUTION ITEMS

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

NOTICE
Park the machine on level ground and check the monitor lamps.
Confirm that these caution lamps light for about 3 seconds after the starting switch is turned to ON. If any monitor lamp does
not light, have your Komatsu distributor inspect and repair it.

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

(1) Engine oil pressure caution lamp (4) Hydraulic oil temperature caution lamp
(2) Engine coolant temperature caution lamp (5) HSS charge pressure caution lamp
(3) Power train oil temperature caution lamp

3 - 11
.

EXPLANATION OF COMPONENTS OPERATION

ENGINE OIL PRESSURE CAUTION LAMP

This lamp (1) indicates low engine oil pressure.
If the monitor lamp flashes, stop the engine and check it
immediately.

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

ENGINE COOLANT TEMPERATURE CAUTION LAMP

This lamp (2) indicates a rise in the coolant temperature.
When the monitor lamp flashes, run the engine at low idle speed
until green range of the engine coolant temperature gauge lights.

POWER TRAIN OIL TEMPERATURE CAUTION LAMP

Lamp (3) warns operator that the torque converter outlet port oil
temperature has risen.
If it flashes, run the engine at low idling until the power train oil
temperature gauge goes down to the green range.

HYDRAULIC OIL TEMPERATURE CAUTION LAMP

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

3 - 12
.

OPERATION EXPLANATION OF COMPONENTS

HSS CHARGE PRESSURE CAUTION LAMP

This monitor (5) warns the operator that the HSS charge pressure
has dropped. If it flashes, stop the engine and carry out inspection.

REMARK
The buzzer may also sound, but this is not an abnormality.

3 - 13
.

EXPLANATION OF COMPONENTS OPERATION

METER GROUP

NOTICE
While the engine is at rest, turn the starting switch to the ON position to see if the engine coolant temperature gauge, power train
oil temperature gauge, fuel level gauge, and monitor lamps all light up.
If they do not, have your Komatsu distributor inspect and repair it.

(1) Engine coolant temperature gauge (7) Torque converter lock-up display indicator
(2) Power train oil temperature gauge (8) Display panel A
(3) Hydraulic oil temperature gauge (speed range display,engine speed)
(4) Fuel level gauge (9) Display panel B(multi-information)
(5) Engine pre-heating pilot lamp
(6) Dual/single tilt selector display lamp
(dual tiltdozer specification)

3 - 14
.

OPERATION EXPLANATION OF COMPONENTS

ENGINE COOLANT TEMPERATURE GAUGE

Gauge (1) indicates temperature of the engine coolant.
If the temperature is normal during operation, green range (B) will
light.
If red range (C) lights during operation, move the fuel control dial to
lower engine speed to approx. 3/4 of the full speed, and run until
the coolant temperature enters green range (B).
During operation, if red range (C) lights, engine coolant
temperature monitor flashes and the alarm buzzer sounds, stop
the machine and run at low idle until coolant temperature enters
green range (B).
(A): White range
(B): Green range
(C): Red range

NOTICE
If the coolant temperature gauge often enters red range (C), check the
radiator for clogging.

POWER TRAIN OIL TEMPERATURE GAUGE

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

NOTICE
If the power train oil temperature gauge often enters red range (C), shift
down one speed range to reduce the load on the power train when
operating.

3 - 15
.

EXPLANATION OF COMPONENTS OPERATION

HYDRAULIC OIL TEMPERATURE GAUGE

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

FUEL LEVEL GAUGE

Gauge (4) fuel level in the fuel tank.
During normal operation, the green range (B) should be lit.
If red range (A) lights up during operation, add fuel immediately. If
this is not done, the engine speed will become irrgular or an error
display will be shown on the monitor.
(A): Red range
(B): Green range

REMARK
The display is not proportional to the amount of fuel remaining.
If only the red range (A) lights up, there is less than 90 liters
(23.78 US gal) of fuel remaining.

ENGINE PRE-HEATING PILOT LAMP

Lamp (5) indicates that engine is being pre-heated by the electrical
heater during cold weather.
The engine controller detects the coolant temperature and
automatically actuates pre-heating in low temperatures when
starting the engine.

3 - 16
.

OPERATION EXPLANATION OF COMPONENTS

DUAL/SINGLE TILT SELECTOR DISPLAY LAMP

(Dual tiltdozer specification)
This lamp (6) lights up when the dual/single selector switch on the
work equipment control lever is set to DUAL.

TORQUE CONVERTER LOCK-UP DISPLAY INDICATOR

Lamp (A) of this indicator (7) lights up when the torque converter
has been automatically locked up (when transmission is set to
direct drive) after lock up switch for the mode selection switch
panel has been turned ON.
The lamp goes out when torque converter drive is being used.

DISPLAY PANEL A (speed range display, engine speed)

Meter (8) displays transmission speed range (B) being used on the
machine and engine speed.
When the transmission is in 1st FORWARD, the display shows
F1, and when it is in 1st REVERSE, the display shows R1.
The peripheral bar graph (A) indicates the engine speed. When
the red range (C) lights up during running, shift the gear to a
lower speed to run the engine at a speed within the green range.

3 - 17
.

EXPLANATION OF COMPONENTS OPERATION

DISPLAY PANEL B (Multi-information)

This monitor (9) displays information related to the condition of the machine on the top and bottom lines of the
display portion. The content of the display can be switched by operating the service mode selector switch.

(1) Operating mode (normal operation screen)

Use this mode when operating the machine.

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

The shift mode selected by operation of the "GEARSHIFTING USING SHIFT MODE SELECTION (PAGE 3-108)"
through the shift mode selection is displayed on the left side of the monitor.
The total operating hours of the machine is displayed at the bottom right of the monitor. (Use the service meter
function display to set the interval for periodic maintenance.)
When the engine is running, the service meter advances, even if the machine is not moving.
When the engine is running, the hourglass mark pilot display at the side of the meter lights up to show that the meter
is advancing.
The meter advances by 1 for every hour of operation, regardless of the engine speed.
If there is a failure in the machine, the failure code is also displayed on the top line. If a failure code is displayed,
carry out the remedy given in "OTHER TROUBLE (PAGE 3-159)".

(2) Maintenance mode

The maintenance mode is displayed by continuing to turn the
buzzer cancel switch in the direction for 2.5 seconds.
For details, see "METHOD OF USING DISPLAY PANEL B
(Multi-information) (PAGE 3-27)".

3 - 18
.

OPERATION EXPLANATION OF COMPONENTS

MODE SELECTION SWITCH GROUP

Press each mode switch to turn it ON or OFF and to select the mode.
For details of setting the mode to use, see "EFFECTIVE USE OF MODE SELECTION SYSTEM (PAGE 3-124)".

Only the reverse slow mode can be selected in combination with the lock-up mode.
The economy mode, and reverse slow mode can be used independently or in combination.

(1) Lock up mode switch (3) Reverse slow mode selector switch
(2) Economy mode switch

Selecting mode to match the type of work and quality of rock and soil makes to perform operations effectively.

Dozing
Reverse slow mode
Lock up mode Economy mode
{ {
{ {

{: Possible to use : Compound use not possible

3 - 19
.

EXPLANATION OF COMPONENTS OPERATION

LOCK UP MODE SWITCH

Switch (1) is used when more power is needed rather than high
production (such as when dozing loose soil).
The drive is switched between torque converter drive and direct
drive according to the load. When it is ON, the lamp lights up.

ECONOMY MODE SWITCH

Switch (2) is used for hauling work after ripping or for dozing
blasted rock.
When the system is OFF, if the switch is pressed once, mode [1]
lights up, and if it is pressed again, mode [2] lights up.
Select the mode according to the type of rock.

REVERSE SLOW MODE SELECTOR SWITCH

Switch (3) is used to make small reductions in the travel speed
when traveling in R1, R2, or R3.
When it is turned ON, the lamp lights up.

3 - 20
.

OPERATION EXPLANATION OF COMPONENTS

SWITCHES

(1) Starting switch (6) Pivot turn switch

(2) Buzzer cancel switch (7) Information switch
(3) Front lamp/ working lamp switch (8) Additional heater switch (if equipped)
(4) Rear lamp switch (9) Fan rotation selector switch
(5) Auto shift down switch

3 - 21
.

EXPLANATION OF COMPONENTS OPERATION

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

(A): OFF position

At this position, the starting switch key can be inserted and
removed. When the switch is turned to this position, all the electric
circuits are turned off and the engine stops.

(B): ON position
In this position, electric current flows in the charging and lamp
circuits.
Keep the starting switch key at the ON position while the engine is
running.

(C): START position

This is the position to start the engine. Hold the key at this position
while cranking the engine. Release the key immediately after the
engine has been started. The key will return to ON position (B)
when released

BUZZER CANCEL SWITCH

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

FRONT LAMP/WORKING LAMP SWITCH

Switch (3) lights up when the front lamp, left and right working
lamps located on the front fender, and panel lamp light up.
(a) OFF position: Goes out
(b) ON position: Lights up

3 - 22
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OPERATION EXPLANATION OF COMPONENTS

REAR LAMP SWITCH

Switch (4) lights up the rear lamp.
(a) OFF position: goes off
(b) ON position: lights up

AUTO SHIFT DOWN SWITCH

When this switch (5) is operated to the right, if the travel speed
drops because of the load conditions when traveling, the
transmission automatically shifts to low speed.
(a) OFF position: Automatic operation canceled
(b) ON position: Automatically shifts down to low speed

For details, see "AUTO SHIFT DOWN OPERATION (PAGE 3-110)".

PIVOT TURN SWITCH

This switch (6) makes it possible to carry out pivot turns.
OFF (a) position: Pivot turns cannot be carried out
ON (b) position: Pivot turns can be carried out

For details, see "MAKING SHARP TURNS TO LEFT WHILE TRAVELING FORWARD (PAGE 3-115)".

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

3 - 23
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EXPLANATION OF COMPONENTS OPERATION

ADDITIONAL HEATER SWITCH

(if equipped)
This switch (8) is used to actuate the hot water heater.
(a) position: Hot water heater OFF
(b) position: Hot water heater Lo (ON)
(c) position: Hot water heater Hi (ON)

FAN ROTATION SELECTOR SWITCH

Set this switch (9) to the (b) CLN position to select the clean mode
for the fan.
When the switch is released, it returns automatically to the (a)
position.
When the clean mode is selected, the fan reversal lamp lights up.
When the clean mode is being used, turn the switch (9) to the right
to return to the normal mode. The fan reversal lamp goes out.

The clean mode is used to blow dust and dirt off the radiator fins. In this mode, the cooling fan rotates at the fullest
speed.
When operating the cooling fan rotation selector switch, turn the engine starting switch key to the OFF position to
make sure that the engine is not running.

REMARK
The cooling fan rotation selector switch does not work when it is operated while the engine is running.
In that case, the fan rotation selection impossibility lamp flashes to indicate that the fan rotation cannot be changed.
The cooling fan rotation selector switch returns to the normal mode, when the engine stops or when the engine
starting switch key is turned to the OFF position.
For cleaning procedures, see"CLEAN AND CHECK RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS
(PAGE 4-37)".

3 - 24
.

OPERATION EXPLANATION OF COMPONENTS

LAMPS

(1) Warning lamp (3) Fan rotation selection impossibility lamp

(2) Fan reversal lamp

3 - 25
.

EXPLANATION OF COMPONENTS OPERATION

WARNING LAMP
(Red)

NOTICE
If alarm buzzer sounds, stop work immediately and perform inspection and
maintenance of the appropriate point.

When the caution lamp for the CAUTION (B) and CAUTION (C)
groups on the machine monitor system flashes, and an failure
code displays it automatically showing an abnormality appears on
monitor panel B (multi-information), lamp (1) also flashes at the
same time.
If a failure code is displayed, carry out the remedy given in
"OTHER TROUBLE (PAGE 3-159)".
If the lamp flashes, check the monitor panel to locate the
abnormality.
When the monitor inside the CAUTION (C) group flashes, the
alarm buzzer also sounds continuously.
See"FRONT PANEL (PAGE 3-5)".

FAN REVERSAL LAMP

This lamp (2) lights up when the clean mode is selected.

FAN ROTATION SELECTION IMPOSSIBILITY LAMP

(Orange)

This lamp (3) lights up at the same time. When the engine is
driving, if the fan rotation selector switch is turned to the (b) CLN
position, this lamp (3) flashes for 3 seconds to show that the
direction of rotation of the fan has not been changed.

3 - 26
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OPERATION EXPLANATION OF COMPONENTS

METHOD OF USING DISPLAY PANEL B (Multi-information)

EXPLANATION OF MODES AND CONTROLS

Display panel B (1) has the function of displaying the following
four types of mode. (The diagram on the right shows the normal
screen before the mode display.)
Maintenance mode
This displays the time for replacing the filters or oil.
PM clinic auxiliary mode
This displays the engine speed and the oil pressure in the
hydraulic circuits.
Fault display mode
This displays the fault code related to the electronic control.
Adjustment mode
This adjusts the brightness and contrast of the display.

There are variations (sub-items) in the four types of mode. For an explanation of the variations, see the following
items.
METHOD OF USING MAINTENANCE MODE (PAGE 3-29)
METHOD OF USING PM CLINIC AUXILIARY MODE (PAGE 3-31)
METHOD OF USING FAULT CODE DISPLAY MODE (PAGE 3-32)
METHOD OF USING USER ADJUST MODE (PAGE 3-33)

Each mode is operated by using information switch (2) and

buzzer cancel switch (3) on the dashboard in front of the
operator's seat.
After operating the switch, release the switch, and the switch will
return automatically to the center position as shown in the
diagram on the right.
The functions of each position of the switches are as follows.
<: Moves mode to left
>: Moves mode to right
: Selects mode
: Cancels mode

The four types of mode can be selected in a cycle by operating information switch (2) to > and < to give the
following sequence: Maintenance mode ←→ PM clinic auxiliary mode ←→ Fault code display mode ←→ Adju
stment mode ←→ Maintenance mode.

From the normal mode before giving the mode display, if buzzer cancel switch (3) is operated to and held for
2.5 seconds, the maintenance mode is displayed. After that, if information switch (2) is operated to >, the mode
changes to the PM clinic auxiliary mode. If information switch (2) is operated to <, the mode changes to the user
adjust mode.

When any mode is being displayed, if the buzzer cancel switch is operated to , the screen returns the normal
screen shown before the mode display.

3 - 27
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EXPLANATION OF COMPONENTS OPERATION

METHOD OF SELECTING MODES

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

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

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

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

3 - 28
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OPERATION EXPLANATION OF COMPONENTS

METHOD OF USING MAINTENANCE MODE

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

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

The display items can be displayed in order by operating the information switch to the left or right (<, >).

1st replacement 2nd and following

Display Item
interval replacement intervals
1. ENG.OIL Engine oil 500h 500h
2. ENG.FLT Engine oil filter 500h 500h
41. F.PRE.FLT Fuel pre-filter 500h 500h
4. FUEL.FLT Fuel filter 1000h 1000h
6. P/L.OIL Power train oil 250h 1000h
7. P/L.FLT Power train oil filter 250h 500h
8. HYD.OIL Hydraulic oil 250h 2000h
9. HYD.FLT Hydraulic oil filter 250h 2000h
10. CHG.FLT HSS charge filter 1000h 1000h
11. DAMP.OIL Damper oi 2000h 2000h
12. FNL.OIL Final drive oil 250h 2000h

3 - 29
.

EXPLANATION OF COMPONENTS OPERATION

When the oil or filter has been replaced, select the applicable item,
then operate the buzzer cancel switch to .
The screen will ask if you want to display the replacement history.
Operate the information switch to select YES, then operate the
buzzer cancel switch to . The replacement account will increase
by 1, the replacement interval will be reset, and the oil, filter change
interval lamp will go out.
When this is done, if the maintenance caution lamp does not go
out, there is another item close to the replacement time, so check
the situation.

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

3 - 30
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OPERATION EXPLANATION OF COMPONENTS

METHOD OF USING PM CLINIC AUXILIARY MODE

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

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

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

Display Item Measured value

01-ENG.SPEED Engine speed Speed (rpm)
02-PUMP PRES Hydraulic oil pressure Pressure (MPa)
03 - -
04-BATTERY VOLT Battery voltage Voltage (mV)
05-HSS PRES.-A HSS A circuit Pressure Pressure (MPa)
06-HSS PRES.-B HSS B circuit Pressure Pressure (MPa)

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

3 - 31
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EXPLANATION OF COMPONENTS OPERATION

METHOD OF USING FAULT CODE DISPLAY MODE

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

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

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

maximum of 20 items.
If multiple failures are occurring, the display automatically changes
every 2 seconds, so check the code (1).
The display is shown repeatedly.

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

3 - 32
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OPERATION EXPLANATION OF COMPONENTS

METHOD OF USING USER ADJUST MODE

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

1. Adjusting backlighting of liquid crystal display

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

The brightness can be adjusted by operating the information

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

When the buzzer cancel switch is operated to , the brightness of

the liquid crystal display backlighting is set.

2. Adjusting backlighting of message display

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

3 - 33
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EXPLANATION OF COMPONENTS OPERATION

The brightness can be adjusted by operating the information

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

When the buzzer cancel switch is operated to , the brightness of

the message display backlighting is set.

3. Adjusting contrast of liquid crystal message display

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

The contrast can be adjusted by operating the information switch.

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

When the buzzer cancel switch is operated to , the contrast of

the liquid crystal display is set.

3 - 34
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OPERATION EXPLANATION OF COMPONENTS

4. Mode to rotate cooling fan at maximum speed

The diagram on the right is the mode for rotating the cooling fan
at maximum speed. On this screen, operate the buzzer cancel
switch to to rotate the cooling fan at the maximum speed.

Note that this mode is effective only when the display in the
diagram on the right is being given. After leaving this mode, the
screen returns to the normal mode.

5. Mode for no-injection cranking

The diagram on the right shows the mode for setting to
no-injection cranking.
Please contact your Komatsu distributor when using this
function.

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

3 - 35
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EXPLANATION OF COMPONENTS OPERATION

SWITCHES

(1) Horn switch (4) Cigarette lighter

(2) Room lamp switch (5) Accessory socket
(3) Wiper switch

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

ROOM LAMP SWITCH

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

3 - 36
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OPERATION EXPLANATION OF COMPONENTS

WIPER SWITCH
Switch (3) activates the wipers.
The wiper switches are as follows:
(A) L.H. door
(B) Front window
(C) R.H. door
(D) Rear window

This is also used as the window washer switch.

The switch is operated as follows.

Window washer only

Keep the switch pressed to the OFF position to spray out water.

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

Wiper and window washer

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

3 - 37
.

EXPLANATION OF COMPONENTS OPERATION

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

(1) Right side (red)

(2) Rear (black)
(3) Front (no color)
(4) Left side (blue)

CIGARETTE LIGHTER
This lighter (4) is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its original
position after a few seconds, so take it out to light your cigarette.
If the cigarette lighter is removed, the socket can be used as a
power source.

NOTICE
This cigarette lighter is 24V. Do not use it as the power supply for 12V
equipment. This will cause failure of the equipment.
The capacity of the cigarette lighter is 120W (24V x 5A).

3 - 38
.

OPERATION EXPLANATION OF COMPONENTS

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

3 - 39
.

EXPLANATION OF COMPONENTS OPERATION

CONTROL LEVERS, PEDALS

(1) Fuel control dial (6) Work equipment lock lever

(2) Joystick (steering, directional and gear shift lever) (7) Blade control lever
(3) Brake pedal (8) Ripper control lever
(4) Decelerator pedal (9) Pin puller control switch (for giant ripper)
(5) Parking brake lever

FUEL CONTROL DIAL

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

REMARK
To stop the engine, turn the starting switch to the OFF position.

3 - 40
.

OPERATION EXPLANATION OF COMPONENTS

JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER)

(PCCS lever)
This lever (2) is used to switch between forward and reverse, to
steer the machine, or carry out counterrotation turns.

REMARK
PCCS: Palm command control system

Forward-reverse shifting
Position (a): FORWARD
Position (b): REVERSE
Position N: Neutral
Move to the front to drive forward; move to the rear to drive in
reverse.

Steering
Position (L): Left turn
Position (R): Right turn
With the lever moved to the front or rear, operate the lever partially to the left or right to turn the machine. The
machine will turn gradually in the same direction as the lever is operated.
If the lever is moved fully to the left or right, the machine will turn in a small radius.

REMARK
When moving the joystick lever, and the lever is released, it will return to (a) or (b) and the machine will travel in a
straight line.

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

REMARK
The speed range being used is displayed on the monitor panel according to the gearshift operation.
<Example>
Neutral:N is displayed on the display panel.
FORWARD 2nd:F2 is displayed on the display panel.
REVERSE 3rd:R3 is displayed on the display panel.
When the parking brake lever is locked,P is displayed
For details of the method of shifting gear according to the shift mode,see the"SHIFTING GEAR (PAGE
3-107)".Shift mode selection means the selected speed range is displayed at the N position before starting.

3 - 41
.

EXPLANATION OF COMPONENTS OPERATION

Operating counter-rotation turn

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

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

3 - 42
.

OPERATION EXPLANATION OF COMPONENTS

BRAKE PEDAL

WARNING
Do not place your foot on this pedal unnecessarily.

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

DECELERATOR PEDAL

WARNING
Do not rest your foot on the pedal if you are not using it.
When passing over the top of a slope or when dumping soil from a cliff, the load on the machine will suddenly be reduced and
the travel speed will increase. This situation is dangerous, so use the decelerator pedal to reduce the travel speed of the
machine

Pedal (4) is used when reducing engine speed or stopping the

machine.
When switching between forward and reverse, or when stopping
the machine, use this pedal to reduce speed.

REMARK
When operating the decelerator pedal, there may be a particular noise, but there is no problem with quality or
durability.

3 - 43
.

EXPLANATION OF COMPONENTS OPERATION

PARKING BRAKE LEVER

WARNING
When the machine is parked, always set the parking brake lever to the LOCK position (L).

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

REMARK
Before moving the parking brake lever to the LOCK position (L), return the steering, directional, and gearshift
lever to the N position.
When starting the engine, if the parking brake lever is not in the LOCK position (L), the limit switch is actuated
and it is impossible to start the engine.

WORK EQUIPMENT LOCK LEVER

WARNING
When standing up from the operator's seat, always move the work equipment lock lever securely to the LOCK position.
If the blade control and ripper control levers are not locked and are touched by accident, it may lead to serious injury or
damage.
If the work equipment lock lever is not completely in the LOCK position (L), the lock may not be applied.
Check that it is in the position shown in the diagram.
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 the LOCK position (L).

Lever (6) is a device to lock the blade control and ripper control
levers.
When it is set to the LOCK position (L), the TILT, RAISE, LOWER,
and FLOAT operations are locked.

REMARK
When starting the engine, to ensure safety, always set the work equipment lock lever to the LOCK position (L).

3 - 44
.

OPERATION EXPLANATION OF COMPONENTS

BLADE CONTROL LEVER

Lever (7) is used to operate the blade.

SINGLE TILTDOZER
This lever is used to carry out the blade lift and tilt operations.

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

REMARK
When released from FLOAT position, this lever (7) will not return to
HOLD position, so it must be returned to HOLD by hand.

Tilting control
(A) RIGHT TILT
(B) LEFT TILT

REMARK
With the tilt operation, the blade can be operated to RAISE, HOLD,
or LOWER.

3 - 45
.

EXPLANATION OF COMPONENTS OPERATION

DUAL TILTDOZER
This lever is used to carry out the blade lift, tilt, and pitch
operations.

(1)Tilt switch
(2)Pitch button

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

REMARK
When released from FLOAT position, this lever (7) will not return to
HOLD position, so it must be returned to HOLD by hand.

Dual tilt operation

Operate the tilt switch (1) to the (D) position.

(A) RIGHT TILT

(B) LEFT TILT

REMARK
With the dual tilt operation, a larger amount of tilt can be obtained than with the single tilt operation.
Use the dual tilt operation to operate the sigmadozer.
With the tilt operation, the blade can be operated to RAISE, HOLD, or LOWER.

3 - 46
.

OPERATION EXPLANATION OF COMPONENTS

Single tilt operation

Operate the tilt switch (1) to the (C) position.

(A) RIGHT TILT

(B) LEFT TILT

REMARK
With the single tilt operation, the tilt amount is less for the left tilt
at rear pitch and for the right tilt at forward pitch.
With the sigmadozer, the rear pitch is the standard pitch, so use
it for dual tilt operation.
For details, see "BLADE CONDITION (PAGE 6-5)".

Pitch control
Rear pitch (R)(cutting angle reduced)
Carry out operation (B) with the pitch button (2) pressed.

Forward pitch (F)(cutting angle increased)

Carry out operation (A) with the pitch button (2) pressed.

REMARK
With the pitch operation, the blade can be operated to any of
RAISE, HOLD, or LOWER.
For details of the effective use of the dual tiltdozer, see
"EFFECTIVE METHOD OF OPERATION FOR DUAL
TILTDOZER (PAGE 6-5)".
To operate the pitch, keep the pitch button pressed and operate
the blade control lever to the left or right to start the operation.
The pitch is the priority circuit, so if the pitch button is pressed
during tilt operation, the pitch will be actuated.

3 - 47
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EXPLANATION OF COMPONENTS OPERATION

RIPPER CONTROL LEVER

(For variable ripper)

Lever (8) is used to operate the ripper.

Lifting control
(a) RAISE
(b) HOLD: Ripper is stopped and held in the same position.
(c) LOWER

Tilting control
(A) Digging angle reduced: Cutting angle (α) becomes smaller.
(B) Digging angle increased: Cutting angle (α) becomes larger.

3 - 48
.

OPERATION EXPLANATION OF COMPONENTS

ADJUSTING FRONT-REAR POSITION OF RIPPER CONTROL LEVER

(Range of adjustment: ± 40 mm (1.6 in))

(F)Front of the machine

Lever (8) position can be adjusted to best suit the operator's physique. Follow the steps below for the adjustment.
Adjustment within range of 40 mm (1.6 in) from neutral to rear
1. Loosen lock nut (1) with a wrench.
2. Set lever (2) to the optimum position.
3. Tighten lock bolt (1) with the wrench to hold lever (2) in position.

Adjustment within range of 40 mm (1.6 in) from neutral to front

1. Remove lock bolt (1) with a wrench.
2. Remove lever (2) and reverse it 180°
3. Install lever (2) to lever (5), then set it to the optimum position.
4. Tighten lock bolt (1) with the wrench to hold lever (2) in position.
5. Loosen nut (3).
6. Reverse knob 180°.
7. Tighten nut (3).

PIN PULLER CONTROL SWITCH (IF EQUIPPED)

Switch (9) is used to operate the pin puller.
(a) PULL OUT: Pin is pulled out.
(b) PUSH IN: Pin is pushed in.

(F)Front of the machine

3 - 49
.

EXPLANATION OF COMPONENTS OPERATION

DUST INDICATOR
This is on the air cleaner bracket inside the engine room.
This device indicates that the air cleaner element is clogged.
For details on how to clean the element, see "CHECK, CLEAN
AND REPLACE AIR CLEANER ELEMENT (PAGE 4-25)".

POWER SOURCE
The cigarette lighter socket (1) can be used as a power source for
24V equipment and the accessory socket (2) can be used for 12V
equipment.

NOTICE
The cigarette lighter is 24V. Do not use it as the power source for 12V
equipment.
The capacity of the cigarette lighter is 120W (24V x 5A).
There are 2 accessory sockets. Their capacity is 60W (12V x 5A).
These 2 accessory sockets only provide power when the starting switch is
ON.

3 - 50
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OPERATION EXPLANATION OF COMPONENTS

FUSE BOX

NOTICE
Before replacing a fuse, be sure to turn starting switch to the OFF position.

The fuses protect the electric equipment and wiring from burning out.
Replace the fuse if it becomes corroded or is covered in white powder, or if there is any looseness between the fuse
holder and the fuse.
Always replace the fuse with a fuse of the specified capacity.

Chassis
Open the fuse inspection cover (A) at the bottom front left of the
operator's compartment. Fuse box is installed inside.

Fuse box (1)

Fuse box (2)
Fuse box (3)

Cab (machines equipped with cab)

Fuse box (4) is installed at the bottom of the overhead panel.

3 - 51
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EXPLANATION OF COMPONENTS OPERATION

FUSE CAPACITY AND NAME OF CIRCUIT

Fuse box (1)

Fuse
NO. Name of circuit
capacity
1 20A VHMS Controller
2 20A Controller Firm Power
3 20A Operator's Cab Firm Power
4 10A 12 V Converter Firm Power
5 20A 12 V Converter Power

Fuse box (2)

Fuse
NO. Name of circuit
capacity
1 5A Back-up alarm
2 5A Pin puller,preheater power source
3 20A Additional heater power source
4 20A Working lamp
5 20A Rear lamp

Fuse box (3)

Fuse
NO. Name of circuit
capacity
1 5A Engine Controller
2 5A Horn
3 20A Spare power source (1)
4 20A Spare power source (2)
5 20A ACC signal

Fuse box (4)

Fuse
NO. Name of circuit
capacity
(1) 10A Car radio, cigarette lighter, room lamp
(2) 10A Rear wiper
(3) 10A R.H. wiper
(4) 10A Front wiper
(5) 10A L.H. wiper
(6) 20A Additional front lamp
(7) 20A Additional rear lamp, revolving lamp
(8) - Spare
(9) - Spare
(10) 10A Radio memory

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OPERATION EXPLANATION OF COMPONENTS

CIRCUIT BREAKER
If the starting switch does not work, open the fuse inspection
cover (A) at the bottom front left of the operator's compartment
and check.

If excessive current flows through the circuit breaker, it cuts off

the electric circuit to prevent damage to the electrical
components and wiring.
To restore the electric circuit after it has been cut off, push in
reset button (1). (This springs out when the circuit is cut off.)
If the electric circuit is normal, reset button (1) will stay pushed
in. If it comes out immediately when it is pushed in, the electric
circuit must be checked.

No. Capacity Circuit

(1) 20A Steering controller
(2) 20A Monitor panel
(3) 20A Transmission controller
(4) 20A Air con main power
(5) 20A Head lamp
(6) 20A Starter switch

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

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EXPLANATION OF COMPONENTS OPERATION

CIRCUIT BREAKER FOR MAIN POWER SUPPLY

If the starting motor does not move when the starting switch is
turned to the START position, open the battery box and check
circuit breakers (A) - (D).
If there is a surge of current, the circuit breaker shuts off the
circuit to protect the electrical components and wiring from
damage.
Turn the starting switch to the OFF position and reset the circuit
breaker.

When resetting the electrical circuit after it has been shut off, press the reset button 5 to 10 minutes after the circuit
has been shut off. When the electrical circuit has been shut off, the operation of the reset button is heavier than
when the circuit is normal. The height of the reset button is the same, regardless of whether the circuit has been
shut off or has been reset, so make note of the effort of the reset button when resetting the circuit.
Do not keep the circuit breaker reset button longer than necessary.
If the starting motor does not work even when the circuit breaker has been reset, contact your Komatsu
distributor.

REMARK
The capacities for circuit breakers (A) - (D) are as follows.
(A): 30A (permanent power supply for cab)
(B): 105A (general power supply)
(C): 30A (power supply for engine controller)
(D): 105A (power supply for heater relay)

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OPERATION EXPLANATION OF COMPONENTS

CAP WITH LOCK

Lock-type caps are available for the radiator water filler, power train case oil filler cap, and hydraulic tank oil filler cap.
For details of the locations of the caps with locks, see "LOCKING (PAGE 3-121)".

OPENING AND CLOSING CAP WITH LOCK

Use the starting switch key to open and close the locks on the caps except fuel tank cap.
The method of opening or closing the locks on the caps are as follows.

OPENING THE COVER

1. Insert the key. 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.

(L) : Lock position

(F) : Open position
(A) : working angle of key 180°
(B) : 45°

2. Turn the key counterclockwise to align the match mark (2) on

the cap with the rotor groove, then turn the cap slowly. When
a click is heard, the lock is released, enabling the cap to be
opened.

LOCKING THE COVER

1. Turn the cap into place.
2. Turn the key clockwise and take the key out.

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EXPLANATION OF COMPONENTS OPERATION

METHOD OF OPENING FUEL CAP

The method of opening or closing the fuel tank cap is as follows.

OPENING THE CAP

1. Raise lever (1) in the (a) direction.
2. When lever (1) is turned in the (c) direction (counterclockwise)
by approx 35°, it stops at the stopper, and the cap can be
opened.

CLOSING THE CAP

1. After turning lever (1) in the (c) direction (counterclockwise),
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.

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OPERATION EXPLANATION OF COMPONENTS

DOOR OPEN LOCK

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

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

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

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EXPLANATION OF COMPONENTS OPERATION

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 the FREE position (F), the glass can be
opened or closed.
When the lever is moved (up or down) to the LOCK position (L),
the glass is fixed in position.
If the glass is not held securely, set the lever in the FREE
position (F) and rotate clockwise (1) to strengthen the holding
power.
To reduce the holding power, turn counterclockwise (2).

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

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

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

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OPERATION EXPLANATION OF COMPONENTS

TOOL BOX
This is inside the front of the right fender.
It is used for storing tools.

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EXPLANATION OF COMPONENTS OPERATION

CAR STEREO, HANDLING

EXPLANATION OF COMPONENTS

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

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

(A) Band display (E) Tape direction display

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

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OPERATION EXPLANATION OF COMPONENTS

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

AUTO-STORE/PRESET SCAN BUTTON

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

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

Preset scan
If this button is pressed for less than 0.5 second while in radio reception, programs from the six preset stations
in the same band will be broadcast one after another for 5 seconds each, starting from No. 1 through No. 6
stations consecutively.
When the desired station is found, press the button again. This stops the preset scan tuning process and switches
to ordinary broadcasting. The same process will be repeated continuously until the button is pressed again.

BASS CONTROL KNOB

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

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EXPLANATION OF COMPONENTS OPERATION

TREBLE CONTROL KNOB

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

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

TIME/RADIO DISPLAY SELECTOR BUTTON

This button (6) is used to switch between the "Radio/tape display"
and the "Time display".

Correcting the time

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

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OPERATION EXPLANATION OF COMPONENTS

TAPE EJECT BUTTON

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

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

FAST FORWARD, REWIND BUTTONS

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

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

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EXPLANATION OF COMPONENTS OPERATION

METAL TAPE BUTTON

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

MANUAL TUNING BUTTONS

These buttons (12) are used for manual tuning.
When "TUN ∧" button is pressed, the frequency goes up; when
"TUN ∨" button is pressed, the frequency goes down. If the button
is pressed down and held, the frequency will change continuously.

SEEK TUNING BUTTONS

These buttons (13) are used to seek tuning.
When the "SEEK UP" button is pressed, the search automatically
goes up; when the "SEEK DN" button is pressed, the search
automatically goes down.
When the next station that can be received is found, it
automatically stops.

BAND SELECTOR BUTTON

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

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OPERATION EXPLANATION OF COMPONENTS

METHOD OF OPERATION

METHOD OF SETTING PRESET BUTTONS

It is possible to preset 6 MW (AM) stations and 12 FM stations (FM1: 6 stations, FM2: 6 stations).

REMARK
If you are playing the cassette, press the tape eject button to stop the tape.

METHOD OF AUTO PRESET

1. Use band selector button (1) to select MW (AM), FM1 or FM2.
2. Press auto-store/preset scan button (2) for less than 0.5
second.
3. The preset scan tuning function automatically searches for the
desired station within the same band and can memorize as
many as 6 stations in the preset memory.

METHOD OF MANUAL PRESET

1. Use band selector button (1) to select MW (AM), FM1 or FM2.
2. Press manual tuning buttons (2) or seek tuning buttons (3).
3. Press preset button (4) of the number to be preset for 2
seconds while the frequency display is being shown on the
display. (The preset channel and frequency are displayed and
the presetting is completed).

4. Repeat the steps explained in Item 2 and 3 above to preset

other stations to the subsequent numbers.
5. If you want to preset a station in the other bands, follow the
steps explained in Item 1 through 4 above.

REMARK
Also, use Steps 2 and 3 when changing the setting of a preset switch to another station.
When the power is disconnected, such as when the battery is replaced, all the settings are deleted, so preset the
stations again.

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EXPLANATION OF COMPONENTS OPERATION

LISTENING TO RADIO
1. Turn the starting switch ON, then turn power switch (1) ON.
2. Use band selector button (2) to select MW (AM), FM1 or FM2.
3. Select the station with the preset buttons (3).

REMARK
In case you do not promptly remember the number assigned to a
certain preset station, press auto-store/preset scan button (4) for
less than 0.5 second. The preset 6 stations will broadcast one after
another for 5 seconds each. When the desired station broadcasts,
press the button again and scan tuning stops.

4. If you want to tune in to a station that is not preset, use either

seek tuning button (5) or manual tuning button (6).
5. Adjust the volume, balance, and tone as desired.
6. When turning the radio OFF, turn power switch (1) to the left
until it clicks.

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

LISTENING TO CASSETTE TAPE

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

3. When finished with the tape, press the cassette eject button to
eject the tape and automatically switch to the radio.

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OPERATION EXPLANATION OF COMPONENTS

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

PRECAUTION WHEN USING

WARNING
If a voltage greater than the specified voltage is input, it may cause fire, electrocution, or other failure. Never input any voltage
other than the specified voltage.
Places inside the radio are under high voltage. Do not remove the cover.
Do not carry out any modifications. This may cause fire, electrocution, or other failure.
If the sound cannot be heard, nothing is displayed, or any other problem occurs, turn off the power switch and ask your
Komatsu distributor to make repairs without delay.

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

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

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EXPLANATION OF COMPONENTS OPERATION

AIR CONDITIONER, HANDLING

GENERAL LOCATIONS OF CONTROL PANEL

(1) Vent selector lever (4) Air flow selector switch

(2) FRESH/RECIRC selector switch (5) Air conditioner switch
(3) Temperature control switch (6) OFF switch

VENT SELECTOR SWITCH (sending air to upper half of cab)

If lever (1) is pulled to position (b), the air from the air conditioner
is all directed to the upper half of the cab.
This can be used when sending a cool breeze during hot weather.

VENT SELECTOR SWITCH (sending air to feet)

If lever (1) is pushed to position (a), the air from the air conditioner
is all directed to the feet.
This can be used to send warm air to the feet during cold weather.

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OPERATION EXPLANATION OF COMPONENTS

FRESH/RECIRC SELECTOR SWITCH (RECIRCULATE)

When switch (2) is pressed, the air inside the cab is recirculated
and no fresh air is taken in from outside. This position is used when
heating or cooling the cab quickly or when the outside air is dirty.

FRESH/RECIRC SELECTOR SWITCH (FRESH)

When switch (2) is pressed, fresh air is taken into the cab during
heating or cooling.
This position is used to bring in clean fresh air into the cab or to
remove the mist from the cab windows.

TEMPERATURE INDICATOR
The further the indicator is in the blue range (B), the lower the
temperature is; the further the indicator is in the red range (R), the
higher the temperature is.
The indicator range is divided into 7 levels, but within each range
the temperature changes sleeplessly.

TEMPERATURE CONTROL SWITCH (COOL)

Use switch (3) to reduce the temperature.
Press this switch to reduce the temperature of the air sent from the
air conditioner.
The lower the temperature becomes, the further the indicator
moves into the blue range.

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EXPLANATION OF COMPONENTS OPERATION

TEMPERATURE CONTROL SWITCH (WARM)

Use switch (3) to increase the temperature.
Press this switch to increase the temperature of the air sent from
the air conditioner.
The higher the temperature becomes, the further the indicator
moves into the red range.

AIR FLOW SELECTOR SWITCH (LO)

Switch (4) is used to set the flow of air from the air conditioner to
LOW.
When this switch is pressed, the air flow is set to the minimum
amount of the three available levels.

AIR FLOW SELECTOR SWITCH (MID)

Switch (4) is used to set the flow of air from the air conditioner to
MID. When this switch is pressed, the air flow is set to the medium
amount of the three available levels.

AIR FLOW SELECTOR SWITCH (HI)

Switch (4) is used to set the flow of air from the air conditioner to HI.
When this switch is pressed, the air flow is set to the maximum
amount of the three available levels.

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OPERATION EXPLANATION OF COMPONENTS

AIR CONDITIONER SWITCH

This switch (5) is used to switch the air conditioner ON/OFF.

REMARK
For machines equipped with a heater only, switch (5) is not available. (Option)

OFF SWITCH
Switch (6) is used to stop operation of the fan.

REMARK
When fresh air is taken into the cab, air pressure in the cab
increases, which prevents the dust from entering. When neither
heating nor cooling is needed, bring in clean fresh air, with your
preferred air flow, to prevent dust from entering the cab.

PRECAUTIONS WHEN USING AIR CONDITIONER

WHEN CARRYING OUT COOLING, VENTILATE THE CAB FROM TIME TO TIME
If you smoke when using the air conditioner, your eyes may start to itch or burn, therefore ventilate the cab every
so often to remove the smoke.
When the air conditioner is used for long periods, carry out ventilation once every hour.

BE CAREFUL NOT TO COOL TOO MUCH

For reasons of health, it is recommended that the cab should feel pleasantly cool when you enter it from the
outside (5 to 6°C (9.0 to 10.8°F) lower than the outside temperature). Pay attention to the temperature when
carrying out cooling.

SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE
If the vents (left and right) in the middle of the dashboard are turned so that cold air plays directly on the cab door
glass, moisture may condense on the outside of the cab door glass and reduce the visibility. (This occurs
particularly in high temperatures.)
If this happens, turn the vent fully to the rear and raise the air conditioner temperature setting slightly.

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EXPLANATION OF COMPONENTS OPERATION

CHECKS DURING OFF-SEASON

Even during the off-season, run the compressor at low speed for several minutes once a week to prevent the loss
of the oil film on the lubricated parts of the compressor. (Run the engine at low speed and set the temperature control
lever to the central position.)

REMARK
When the ambient temperature is low, if the compressor is suddenly run at high speed, it may cause failure of the
compressor. Note that the system is set so that the compressor will not run when the cooler switch is turned on, if
the ambient temperature is less than 2 to 6.5°C (35.6 to 43.7°F).

PROCEDURE FOR REPLACING RECEIVER

Replace the receiver once every 2 years.
After replacing the receiver, add compressor oil. Turn the receiver at an angle and measure the oil remaining inside
the receiver, then add the same amount of oil (Denso Oil 6) to fill the receiver.

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

PRECAUTIONS WHEN REPLACING RECEIVER

If the receiver is left for more than 15 minutes with the blind cover removed, the moisture in the air will be
absorbed, and this will reduce the life of the desiccant. If you remove the blind cover, connect the piping quickly,
evacuate the system and fill with refrigerant.
When removing the refrigerant from the refrigerant circuit, release it gradually from the low pressure side to
prevent oil from flowing out.

CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL

If the compressor belt is loose, or the refrigerant level is low, cooling is not carried out efficiently.
For details, see "WHEN REQUIRED (PAGE 4-22)".

CLEANING AIR FILTER

If the air filter for the FRESH or RECIRC air intake becomes clogged, the cooling or heating capacity will drop.
To prevent this, clean the air filter with compressed air once a week.
For details of the cleaning method, see "WHEN REQUIRED (PAGE 4-22)".

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OPERATION OPERATION

OPERATION
CHECK BEFORE STARTING ENGINE, ADJUST

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.
Also check for loose wiring, play, and collection of dust at places that reach high temperature.

WARNING
Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the engine muffler or
turbocharger, may cause fire.
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.
Do not get on or off the machine from the rear. Using this position is dangerous because it is easy to slip and you cannot be
seen from the operator's compartment. Always use the handrail and step at the side when getting on or off the machine.

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

Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or
leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system. Check also for
loose wiring, play, and collection of dust at places which reach high temperatures.
Always carry out the items in this section before starting the engine each day.

1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses
Check for cracks, excessive wear, play in wotk equipment, cylinders, linkage, and hoses. If any abnormality is
found, repair it.

2. Remove dirt and debris from around the engine, battery, and radiator
Check for dirt accumulated around the engine or radiator. Also check for flammable material (dry leaves, twigs,
grass, etc.) accumulated around the battery, engine muffler, turbocharger, or other high temperature engine
parts. If any dirt or flammable materials are found, remove them.
For the method of removing dirt from the radiator, see "CLEAN AND CHECK RADIATOR FINS, OIL COOLER
FINS, AFTERCOOLER FINS (PAGE 4-37)".

3. Check for coolant and oil leakage around the engine

Check for oil leakage from the engine and coolant leaks from the cooling system. If any abnormality is found,
repair it.

4. Check for leakage from fuel line.

Check that there is no leakage of fuel or damage to the hoses and tubes. If any problem is found, carry out
repairs.

5. Check for leakage of oil from power train case,final drive case,hydraulic tank,hose,joints
Check that there is no oil leakage.If any abnormality is found,repair the place where the oil is leaking.
Check for leakage of oil from the undercover.Check the ground for traces of oil leakage.

6. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers
If any damage, wear, or oil leakage is found, repair the problem and tighten the bolts.

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OPERATION OPERATION

7. Check for damage to handrail and loose bolts

Repair any damage and tighten any loose bolts.

8. Check for damage to gauges, lamps on the instrument panel, and loose bolts
Check for damage to the panel, gauges, and lamps. Replace any damaged parts. Clean off any dirt on the
surface.

9. Check for damage to seat belt and mounting clamps

Check that there is no abnormality in the seat belt or mounting clamps. If there is any damage, replace with new
parts.

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OPERATION OPERATION

CHECK BEFORE STARTING

Always check the items in this section before starting the engine each day.

CHECK MACHINE MONITOR

1. Turn starting switch (1) to the ON position (B).

2. Check that the monitor and gauges light for 3 seconds, and the
alarm buzzer sounds for 1 seconds.

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

NOTICE
Do not simply use the monitor to carry out the check before starting. Always carry out the check before starting according to the
procedure on the following pages.

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OPERATION OPERATION

CHECK COOLANT LEVEL, ADD COOLANT

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

1. Open the side cover on the left side of the machine, then
remove cap (2) and check that the water level in the reserve
tank is between the FULL and LOW marks. If the water level
is low, add water as follows.

2. If the reserve tank becomes empty, there is probably water

leakage. After checking, repair any abnormality immediately. It
no abnormality is found, check the level of the water in the
radiator. If it is low, add Supercoolant (AF-NAC) of the same
density as the Supercoolant in the radiator, then add
Supercoolant to the reserve tank.
3. To refill the radiator, first stop the engine and pour coolant until
it reaches the top of the filler opening. Then start the engine,
after idling for 5 minutes recheck the coolant level, add coolant
if necessary.
4. After adding coolant, tighten the cap securely.

NOTICE
Do not rely solely on the monitor for checking the coolant level.

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OPERATION OPERATION

CHECK FUEL LEVEL, ADD FUEL

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

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

2. After completing work, fill the fuel tank through fuel filler port
(F).
Check the fuel level with the fuel gauge at the fuel filler port.
3. After adding fuel, tighten the cap securely.
Fuel capacity: 840 liters (221.93 US gal)

REMARK
When carrying out operations on slopes, to prevent the engine
from sucking in air, pay careful attention to the amount of fuel
remaining in the tank.
If breather (1) becomes clogged, the pressure inside the tank
will go down, and no fuel may be supplied, so clean the breather
from time to time.

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OPERATION OPERATION

CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT

1. Open the side cover on the left side of the machine.
The water separator forms one unit with the fuel pre-filter and
is at the bottom.

2. It is possible to judge the water level and amount of sediment

by looking through transparent cap (2). If there is any water or
sediment collected at the bottom, set a container to catch the
drain water under drain hose (3).

3. Loosen plug (1) and drain the water.

4. When fuel comes out from drain hose (3), tighten plug (1) immediately.
Tightening torque: 0.2 to 0.45 Nm (0.02 to 0.046 kgm, 0.1 to 0.3 lbft)

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OPERATION OPERATION

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil
temperature to go down before performing this operation.

1. Open the engine side cover on the left side of the chassis.
2. Remove dipstick (G), and wipe the oil off with a cloth.

3. Fully insert dipstick (G) into filler pipe, then remove it.
4. The oil level should be between the H and L marks on the
ENGINE STOPPED side of dipstick (G).
If the oil level is below the L mark, add oil through oil filler (F).

5. If the oil level is correct, tighten the oil filler cap securely and
close the engine side cover.

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OPERATION OPERATION

6. If the oil is above the H mark, remove drain plug (1), loosen
drain valve (2) to drain the excess oil, then check the oil level
again.

REMARK
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the
engine before checking.
If the machine is at an angle make it horizontal before checking.
When adding oil, remove the dipstick form the holder to release the air inside the crankcase.
The dipstick is marked with the levels for "ENGINE STOPPED" on one side and "ENGINE IDLING" on the other
side.
It is also possible to check the oil level with the engine idling, but be sure to remember the following points.
· Check oil when the engine coolant temperature gauge is within the green range.
· Read the dipstick on its reverse side marked with "ENGINE IDLING".

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OPERATION OPERATION

CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL

1. Remove dipstick (G), and wipe the oil off with a cloth.
2. Fully insert dipstick (G) into filler pipe, then remove it.

3. Check that the oil level is between the H and L marks on

dipstick (G).
If the oil level is below the L mark, add oil through oil filler (F).
The dipstick has two sides for checking the oil level: COLD
STOP for use when the engine is stopped and the oil
temperature is low; and HOT IDLE for use when the engine is
idling and the oil temperature is high.

REMARK
When checking the oil level with the engine stopped before starting operations, check the oil level with the side
marked COLD STOP. It is also possible to check the oil level even after starting operations when the power train
oil temperature is high,
but in this case, run the engine at idling and use the side marked HOT IDLE.

4. If the oil is above the H line, remove drain cover (1) at the left
side at the bottom surface of the power train case, pull out drain
hose (2) from the take-out port, loosen drain plug (3), drain the
excess oil, then check the oil level again.

5. If the oil level is correct, tighten the oil filter cap securely.

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

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OPERATION OPERATION

CHECK BRAKE PEDAL TRAVEL

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

CHECK DUST INDICATOR

1. Check for the yellow piston overlapping the red zone on the
dust indicator (1).
2. If the yellow piston is overlapping the red zone, clean or
replace the element immediately.
For details of the method of cleaning the element, see
"CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
(PAGE 4-25)".

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

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

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OPERATION OPERATION

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

WARNING
When removing the oil filler cap, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn
the cap slowly to release the internal pressure before removing the cap.
If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down. Then remove drain plug
(P), loosen drain valve (1), and drain the excess oil.

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

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

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

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

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OPERATION OPERATION

CHECK ELECTRIC WIRING

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

Check for damage and wrong capacity of the fuse and any sign of disconnection or short circuit in the electric wiring.
Check also for loose terminals and tighten any loose parts.
Check the wiring of the "battery", "starting motor" and "alternator" carefully in particular.
Always check if there is any accumulation of flammable material around the battery, and remove such flammable
material.
Please contact your Komatsu distributor for investigation and correction of the cause.

CHECK THAT LAMPS LIGHT UP

1. Turn starting switch (1) to the ON position (B).

2. Turn the front lamp and working lamp switch to the ON (b)
position, make sure the lamps light up.

3. Turn the rear lamp switch to the ON (b) position, make sure the
lamps on the left and right fenders light.
If the lamps do not light, check for a broken bulb or disconected
wire, contact your Komatsu distributor for repairs.

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OPERATION OPERATION

CHECK HORN SOUND

1. Turn starting switch (1) to the ON position (B).

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

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OPERATION OPERATION

CHECK BACKUP ALARM SOUND

1. Turn starting switch to the ON position (B).

2. Set parking brake lever to the FREE position (F).

3. While depressing the brake pedal, set joystick to the

REVERSE position (b).
The buzzer must sound immediately.
Buzzer will continue to sound until the joystick is moved to
NEUTRAL position (N) or FORWARD position (a).

4. As soon as it is confirmed that the buzzer is working properly,

set the joystick to the NEUTRAL position (N), put the parking
brake lever to the LOCK position (L), and then release the
brake pedal.

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OPERATION OPERATION

ADJUSTMENT

ADJUSTING OPERATOR'S SEAT

WARNING
Adjust the seat position at the beginning of each shift or when operators change.
Adjust seat so the brake pedal can be completely depressed with the operator's back against the backrest.

(A) Fore-and-aft adjustment

Pull lever (1), set the seat to a position where it is easy to operate,
then release the lever.
Fore-aft adjustment: 200 mm (7.9 in) (10 stages)

(B) Weight and height adjustment of seat

Turn knob (2) under the seat so that weight adjustment indicator
(3) displays the green range. The height can be adjusted by
turning the knob (2) while the green range is displayed.
Turn the knob clockwise to raise the seat and turn the knob
counterclockwise to lower the seat.
Height adjustment range: stepless, 75 mm (3 in)
Weight adjustment range: 50 to 130 kg (110 to 237 lb)

(C) Adjust reclining angle

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

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

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OPERATION OPERATION

(D) Adjusting direction of seat

Pull lever (5) up to FREE position (F) to release the lock. It is then
possible to change the direction of the seat to a position facing 15
° to the right.
After changing the direction of the seat, return the lever securely to
LOCK position (L).
Change the direction of the seat to the right for the ease of
operation of the ripper.

REMARK
If the direction of the seat is changed, the steering, directional, and gearshift lever is also interconnected and
changes direction.

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OPERATION OPERATION

USING SEAT BELT

Always install a seat belt on machines equipped with ROPS.

WARNING
Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions.
Replace any worn or damaged seat belt or the securing brackets.
Even no problem can be seen with the belt, always replace the seatbelt once every three years. The date of manufacture is
given on the rear side of the belt.
Adjust and fasten the seat belt before operating the machine.
Always use the seat belt when operating the machine.
Fit the seat belt across your lap without twisting.

FASTEN THE BELT AND REMOVE IT

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

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

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

6. When removing the belt, press the red button on buckle (3).
The belt will automatically retract.
Check that the bolts of the clamp securing the belt to the chassis are not loose. Tighten them if they are loose.
Tightening torque: 24.5 ± 4.9 Nm (2.5 ± 0.5 kgm, 18.1 ± 3.6 lbft)
If the seat belt is scratched or frayed, if any fittings are broken or deformed from long service, replace the seat belt
immediately.

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OPERATION OPERATION

ADJUST MIRROR

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 injure someone seriously.

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

ADJUST JOYSTICK (PCCS LEVER)

WARNING
After moving case (2) in order to adjust the position of the steering, directional, and gearshift lever, secure lock lever (1) into the
notched hole, making sure it is in the LOCK position. If it is not completely locked, the steering, directional, and gearshift lever
may unexpectedly move and cause damage, serious injury, or death.

The steering, directional, and speed lever (wrist control type single lever: joystick) can be adjusted by 100 mm (3.9
in) in 5 stages to the front or rear. Adjust to the most suitable position to match the adjustment of the operator's seat.
1. Pull up lock lever (1) to the FREE position (F) at the rear of case
(2) on left side of the operator's compartment.

2. With lock lever (1) pulled up, use your other hand to grip the
front of case (2), then move it forward with your left and right
hands. The joystick moves with case (2).

3. Move case (2) to the desired position until a click is heard.

Then pull up lock lever (1) and release it. Lock lever (1)
automatically returns to the LOCK position.
(a) Front
(b) Rear

REMARK
PCCS: Palm command control system

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.

OPERATION OPERATION

ADJUST ARMREST
The height of the armrests on the right and left sides of the operator's seat can be adjusted according to the following
procedure. After adjusting the operator's seat, adjust the armrest height properly.

ADJUST ARMREST (RIGHT)

Armrest (1) on the right side of the operator's cab part can be adjusted up 30 mm (1.2 in) or down 30 mm (1.2 in)
based on the standard height (center) in three stages.

1. Loosen knob (2) (2 places).

2. Move the armrest on the operator's seat to the front, then align
the position of the 3 holes {high (H), middle (M), low (L)}.

3. Tighten knob (2) securely.

ADJUST ARMREST (LEFT)

The armrest on the left side of the operator's compartment can be adjusted to 2 heights.

1. When adjusting height of both armrest and case

It is possible to effortlessly adjust the standard height up 50
mm (2 in) or down 50 mm (2 in).
The steering, directional, and gearshift lever moves as a unit.

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

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

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OPERATION OPERATION

2. When adjusting height of armrest only

It is possible to effortlessly adjust up to 36 mm (1.4 in) upward
from the armrest and case contact surface.
The steering, directional, and gearshift lever does not move.

Open the armrest, and turn knob (2) counterclockwise to adjust

the height.
Only the armrest will move up. After adjusting it to the desired
height, close the armrest.

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OPERATION OPERATION

OPERATIONS AND CHECKS BEFORE STARTING ENGINE

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

1. Check that parking brake lever (1) is locked.

If this lever is not in the LOCK position (L), the engine will not
start.

2. Check that joystick (2) is in the N (neutral) position.

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

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OPERATION OPERATION

3. Lower the blade to the ground to check that blade control lever
(3) is in HOLD position (b).

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

5. Check that the work equipment lock lever (4) is LOCK position
(L).

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OPERATION OPERATION

STARTING ENGINE

NORMAL STARTING
WARNING
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.
Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.

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

1. Set the fuel control dial to the low idling (MIN) position.
If it is at the high idling (MAX) position, always change it to
the low idling (MIN) position.

2. Insert the key into starting switch (2) and turn the key to the
START position (C). The engine will start.

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.

OPERATION OPERATION

3. When the engine starts, release the key in starting switch (2).
The key will return automatically to the ON position (B).

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.

OPERATION OPERATION

STARTING IN COLD WEATHER

WARNING
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.
Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Never use starting aid fluids as they may cause explosions.
Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.

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

1. Set the fuel control dial to the low idling (MIN) position.
If it is at the high idling (MAX) position, always change it to
the low idling (MIN) position.

2. Insert the key into starting switch (2) and turn the key to the ON
position (B).

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OPERATION OPERATION

3. Check that engine pre-heating pilot lamp (3) on the monitor

panel lights up.

4. Maintain the key in the on position until the preheating pilot

lamp (3) goes off.

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

Ambient temperature Pre-heat time

-5°C to -10°C (23°F to 14°F) 20 to 27 seconds
-10°C to -20°C (14°F to -4°F) 27 to 40 seconds
-20°C to -30°C (-4°F to -22°F) 40 seconds

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OPERATION OPERATION

6. When the engine starts, release the key in starting switch (2).
The key will return automatically to the ON position (B).

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

7. When the engine rotation stabilizes, return to the low idle (MIN) position of fuel control dial (1) and then carry out
the warming-up operation.

REMARK
Regardless of the ambient temperature, if the key in starting switch (2) is turned from OFF position to left,
preheating pilot lamp (3) will light up and preheating will start. (Preheating continues while the starting switch is
held at the left.)
For the details of the preheating time, see the table in Step 5.
While preheating is being carried out, the preheating pilot lamp (3) lights up to show that preheating is being
carried out. After it lights up for 36 seconds, it flashes for 16 seconds and goes out. When it goes out, complete
the preheating immediately.
If the engine does not start with the above operation, wait for about 2 minutes, and repeat steps from Step 3. And
4.
The relationship between the actuation time of the turbo protect function and the engine cooling water
temperature is as follows.
Even if the fuel control dial is operated within the time given below, the engine speed will not change.

Coolant temperature Turbo protect time (sec.)

Above 10°C (50°F) 0
10 to -10°C (50 to 14°F) Change 0 to 20
below -10°C (14°F) 20

In cold weather, the turbo protect function is actuated, so the engine speed is kept at 1000 rpm or below for
several seconds. After that, it becomes the speed set by the position of the fuel control dial.

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OPERATION OPERATION

OPERATIONS AND CHECKS AFTER STARTING ENGINE

WARNING
If there has been any Emergency stop, abnormal actuation or trouble, turn the starting switch key to the OFF position.
If the work equipment is operated without sufficiently warming the machine up, 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 cold areas, be sure the warming-up operation is completed.

CHECKING OF ENGINE STARTABILITY AND NOISE

When starting the engine, check that the engine causes no abnormal noise and that it starts up easily and smoothly.
Check also that there is no abnormal noise when the engine is idling or when the revolution rises slightly.
When there is an abnormal noise at the engine startup and if that condition continues, the engine may be
damaged. In that case, ask your Komatsu distributor to check the engine as soon as possible.

CHECKING OF ENGINE ACCELERATION AND DECELERATION

Check that there is no irregularity in the engine speed and that the engine does not suddenly stop when the machine
is stopped during normal travel.
Check also that the engine accelerates smoothly when the accelerator pedal is depressed.
Carry out the inspection in a safe place and check that there is no one in the surrounding area.
If the condition at low speed or when accelerating is extremely poor and that condition continues, there is danger
that the engine may be damaged, that the operating feeling may become strange, that the braking effect may
deteriorate, or that an unexpected accident may happen, so please ask your Komatsu distributor to carry out
repairs as soon as possible.

BREAKING IN THE MACHINE

NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the
machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).

Make sure that you fully understand the content of this manual, and pay careful attention to the following points when
breaking in the machine.
Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and
sudden changes in direction.

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OPERATION OPERATION

WARMING UP OPERATIONS

NOTICE
Do not perform operations or suddenly operate the levers when the
hydraulic oil is at a low temperature. Always perform the warming-up
operation until the hydraulic oil temperature monitor displays the green
range. This will help extend the machine life.
Do not suddenly accelerate the engine before the machine reaches full
operating temperature.
Do not run the engine at low or high idle for more than 20 minutes. This
will cause oil leaks from the turbocharger oil supply piping.
If it is necessary to run the engine at idling, apply a load from time to
time or run the engine at a mid-range speed.
If engine oil pressure caution lamp (3) flashes or the buzzer sounds
intermittently, stop the engine and check for the cause.

1. Turn fuel control dial (1) to the center position between LOW
IDLE (MIN) and HIGH IDLE (MAX) and run the engine at
medium speed for about 5 minutes with no load.

2. After warm-up is completed, check gauges and caution lamps

for proper operation. If any problem is found, repair it.
Continue to run the engine under a light load until engine
coolant temperature gauge indicator (2) is within the green
range (B).

(A): White range

(B): Green range
(C): Red range

3. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu
distributor.

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OPERATION OPERATION

IN COLD AREAS
(AUTOMATIC WARMING-UP OPERATION)
This machine is equipped with an automatic warming-up device.
When the engine is started, if the engine coolant temperature is low (below 30 °C (86 °F)), the warming-up
operation is carried out automatically.
The automatic warming-up operation is canceled if the engine coolant temperature reaches the specified
temperature (30 °C (86 °F)) or if the warming-up operation is continued for 10 minutes. If the engine coolant
temperature or hydraulic oil temperature are low after the automatic warming-up operation, warm the engine up
further as follows.

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

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

keep the blade raised to the maximum height and continue to
relieve the circuit for 10 minutes.
3. Finally, operate blade control lever (4) and ripper control lever
to operate the blade and ripper cylinders several times.
If the oil temperature in the work equipment is not properly
raised, there will be a time lag in the response of the work
equipment and steering.

4. After warm-up is completed, check gauges and caution lamps

for proper operation. If any problem is found, repair it.
Continue to run the engine under a light load until engine
coolant temperature gauge indicator (2) is within the green
range (B).
(A): White range
(B): Green range
(C): Red range

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

5. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu
distributor.

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OPERATION OPERATION

STOPPING ENGINE

NOTICE
If the engine is stopped without allowing it to cool down, there is danger
that the service life of various parts of the engine will be reduced. Except
in emergencies, never stop the engine suddenly.
If the engine overheats, do not stop it suddenly. Run it at low speed to
allow it to cool down gradually, then stop it.

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

2. Turn the key in ignition switch (2) to the OFF position (A).
The engine will stop
3. Remove the key from starting switch (2).

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OPERATION OPERATION

MOVING MACHINE
WARNING
Before moving the machine, check that the area around the machine is
safe, and always sound the horn before moving.
Do not allow anyone to enter the area around the machine.
The rear of the machine is a blind spot, so be extremely careful when
traveling in reverse.
When moving the machine down a slope, always keep brake pedal (8)
depressed, even after releasing parking brake lever (1).
When moving the machine up a steep slope, turn fuel control dial (5) to
high idling (MAX) position and run the engine at full speed, and keep
brake pedal (8) and decelerator pedal (6) depressed. Then operate
steering, directional, and gearshift lever (4) from the N (neutral) position
to the direction of travel and slowly release brake pedal (8). When the
travel speed rises, slowly release decelerator pedal (6).

CAUTION
When the cooling fan rotation selector switch is in the clean mode, and
parking brake lever (1) is released, "N" on the monitor display flashes and
the machine does not start up. To release the clean mode, stop the engine
and turn the selector switch to the normal mode.

1. Operate parking brake lever (1) to the FREE (F) position.

2. Operate work equipment lock lever (2) to the FREE (F)

position.

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OPERATION OPERATION

3. Operate blade control lever (3) and ripper control lever (4) to
the RAISE (a) position so that the blade will rise above the
ground by 40 cm to 50 cm (15.8 in to 19.7 in) and the ripper will
rise to the upper limit.

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

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

gradually release decelerator pedal (6) and allow the machine
to move.

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.

OPERATION OPERATION

STOPPING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.

1. Depress brake pedal (1) to stop the machine.

NOTICE
If the brake is depressed when the engine speed or travel speed is high, the
brake disc may make a slipping sound. Normally, depress decelerator
pedal (3) to reduce the engine speed and travel speed before depressing
the brake.

2. Return steering, directional, and gearshift lever (2) to the N

position, depress brake pedal (1) further and stop the machine.

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OPERATION OPERATION

SHIFTING GEAR
The machine does not have to be stopped to shift gears.
1. Move steering, forward-reverse, gear shift lever (1) to the
desired gear position to shift gears.

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

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

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

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

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OPERATION OPERATION

GEARSHIFTING USING SHIFT MODE SELECTION

Shift mode selection means that the selected speed range is
displayed in the N position before starting.
When the joystick is in the N position, if UP switch (a) or DOWN
switch (b) is pressed, the shift mode selection can be carried
out.

The selected shift mode is displayed on display panel B

(multi-information) of the monitor panel.

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OPERATION OPERATION

Shift operation when [F1-R2] mode is set

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

Shift operation when [F2-R2] mode is set

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

REMARK
Even when the transmission is set to [F1-R1] mode, [F1-R2] mode, or [F2-R2] mode, if the UP switch or DOWN
switch is operated, this will be given priority and manual operation can be carried out.
For example: After the [F1-R2] mode has been set, if the joystick is operated forward (to set to FORWARD), the
speed range is set to F1. However, if the lever is kept operated forward and UP switch (a) is pressed
once, the speed
range will shift to F2; if the UP switch is pressed twice, the speed range will shift to F3. When the
transmission is in F3 and DOWN switch (b) is pressed once, the speed range will shift to F2; if the
DOWN switch is pressed twice, the speed range will shift to F1.
On the other hand, if the joystick is operated to the rear (to set to REVERSE), the speed range is
automatically switched R1 → R2. However, if the lever is kept operated to the rear and UP switch (a)
is pressed once,
the speed range will shift to R3; if the DOWN switch (b) is pressed once, the speed range will shift to
R1.
However, the setting stays in the [F1-R2] mode. If the steering, directional, and gearshift lever is
returned to N and then operated forward (to set to FORWARD), the speed range is set to F1; if the
lever is operated to the rear (to set to REVERSE), the speed range is automatically switched R1 →
R2.
The default setting is [F1 - R1].
After the starting switch is turned OFF, the shift mode returns to the default setting [F1 - R1].

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OPERATION OPERATION

AUTO SHIFT DOWN OPERATION

If the travel speed has gone down because of the load condition
when traveling, the transmission is automatically shifted to low
speed. Set auto shift down switch (2) on the instrument panel in
front of the operator's seat to the b (ON) position to actuate the auto
shift.

OFF position (a): Automatically canceled

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

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

F2, R2 → R1, R3 → R2.

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OPERATION OPERATION

REMARK
For safety reasons, during auto shift down, the transmission is
prevented from shifting up.
If it is desired to shift up, use manual control and press the UP
button on the steering, directional, and gearshift lever.

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OPERATION OPERATION

SHIFTING BETWEEN FORWARD AND REVERSE

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

CAUTION
There is no need to stop the machine even when switching between
FORWARD and REVERSE.
To increase safety, operator comfort, and the life of the transmission, leave
the engine running at full speed, and always depress the decelerator pedal
to lower the engine speed.

1. Depress decelerator pedal (1) to reduce the engine speed.

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

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

3. After depressing decelerator pedal (1), move steering,

forward-reverse, gear shift lever (2) to the desired position.

(F) Forward
(N) Neutral
(R) Reverse

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OPERATION OPERATION

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

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

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OPERATION OPERATION

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

NORMAL TURNING
To turn the machine while traveling, incline steering,
forward-reverse, gear shift lever (1) in the direction of the turn.

TURNING GRADUALLY TO LEFT WHILE TRAVELING FORWARD

If the joystick is pushed forward and moved partially to the left (L),
the steering clutch is disengaged and the machine turns gradually
to the left.

When turning gradually to the right, push the joystick forward, and
move it partially to the right.
Do the same when traveling in reverse.

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OPERATION OPERATION

MAKING SHARP TURNS TO LEFT WHILE TRAVELING FORWARD

When the pivot turn mode switch is turned ON, pivot turns can be
carried out in F1, R1, F2, or R2.
If the joystick is pushed forward and moved fully to the left (L), the
steering clutch is disengaged, the brake is applied, and the
machine turns sharply to the left.
The pivot turn mode provides excellent ability to turn in a small
radius when the road surface resistance is light.
When operating under heavy load, select the normal turn mode.

COUNTERROTATION TURNS TO LEFT WHEN TRAVELING FORWARD

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

With steering, forward-reverse, gear shift lever (1) in the N

position, operate the lever partially to the left (L). The left and right
tracks will rotate in opposite directions, and the machine will make
a slow counterrotation turn. If the lever is moved further, the speed
of the counterrotation turn will increase.

REMARK
When making a right counterrotation turn, move the steering,
forward-reverse, gear shift lever (1) to the right (R) in the same
way.

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OPERATION OPERATION

TURNING WHILE DESCENDING A SLOPE

TURNING GRADUALLY TO LEFT WHILE TRAVELING FORWARD

If the joystick (1) is pushed forward and moved partially to the left
(L), the machine turns gradually to the left.

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

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OPERATION OPERATION

PRECAUTIONS FOR OPERATION

PAY ATTENTION TO GAUGES

If the red range of the power train oil temperature gauge lights up during operation, reduce the load and wait for the
temperature to go down.

PERMISSIBLE WATER DEPTH

When operating in water, always keep top surface of the track
frame above the surface of the water.
Also, be careful that the engine cooling fan will not come in contact
with water. The fan can be damaged.

(A): Permissible water depth line

PRECAUTIONS WHEN TRAVELING FOR A LONG TIME

Avoid operating the machine at high speed for a long time,
otherwise the temperature of hydraulic 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 UP OR DOWN HILLS

METHOD OF USING DECELERATOR PEDAL

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

USE ENGINE AS BRAKE

When going downhill, move steering, forward-reverse, gear shift lever into low speed to run engine at slow speed
and travel down slope using the engine as a brake.
Do not move the steering, forward-reverse, gear shift lever to the NEUTRAL position.
When traveling down hills of more than 15°, shift down to 1st speed (R1 or F1).

BRAKING WHEN TRAVELING DOWNHILL

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

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OPERATION OPERATION

PRECAUTIONS ON SLOPE

BE CAREFUL OF FUEL LEVEL

If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle
of the machine or the swaying of the machine. This makes the engine stop, so be careful not to let the fuel level in
the fuel tank become too low.

BE CAREFUL OF OIL LEVEL

When operating machine on sloped areas of more than 20°, fill all appropriate components with oil to H level.

PRECAUTIONS WHEN ENGINE STOPS ON SLOPE

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

METHOD OF USING BRAKES

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

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

PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS

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

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

For safety reasons, do not install anything on the cab glass that will obstruct the view.
Always keep the glass clean to ensure safety during operations.

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OPERATION OPERATION

PARKING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
When stopping the machine, select flat hard ground and avoid
dangerous places. If it is unavoidably necessary to park the machine on
a slope, place the parking brake lever (4) in the LOCK position and insert
blocks underneath the track shoes. As an additional safety measure,
thrust the blade into the ground.
If the work equipment control lever is touched by accident, the work
equipment may suddenly move, and may cause damage, serious injury,
or death. Before leaving the operator's seat, always secure work
equipment lock lever (7) in the LOCK position.

1. Depress brake pedal (1) to stop the machine.

NOTICE
If the brake pedal is depressed when the engine speed or machine travel
speed is high, the brake disc may produce a slipping sound. When
depressing the brake pedal, usually depress decelerator pedal (2) to
reduce the engine speed and machine travel speed.

2. Set joystick (steering, directional, and gearshift lever) (3) to the

N position.

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OPERATION OPERATION

3. Operate parking brake lever (4) to the LOCK (L) position.

4. Operate blade control lever (5) and ripper control lever (6) to
the LOWER (c) position to lower the blade and ripper to the
ground.
5. Operate blade control lever (5) and ripper control lever (6) to
the HOLD (b) position.

6. Set work equipment lock lever (7) to the LOCK position (L).

CHECK AFTER STOPPING ENGINE

1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for
any leakage of oil or coolant. If any problems are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud affixed to the undercarriage.

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OPERATION OPERATION

CHECK AFTER FINISHING WORK

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

LOCKING
Places that can be locked with the starting switch key.

To prevent vandalism, there are locks in the following places.

Left-and-right engine side covers (1)
(left side: 2 places, right side: 2 places)
Right and left covers (2) at rear of fender (left side: 1 place, right
side: 1 place)
Cab door opener (3)
Battery inspection cover (4)
Tool box inspection cover (5)
Lock-type caps (6)
Radiator cap
Hydraulic tank cap
Power train oil filler pipe cap

Padlock
Fuel tank cap (7)

REMARK
If the padlock (A) is to be used, it is recommended to use the type
that has the cover to protect the key hole.

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OPERATION OPERATION

WORK POSSIBLE USING BULLDOZER

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

DOZING
A bulldozer digs and transports dirt in a forward direction. Slope
excavation can always be most effectively carried out by
proceeding from the top downward.

CUTTING INTO HARD OR FROZEN GROUND OR DITCHING

For digging and ditch excavation of hard or frozen ground tilt the
blade. Even hard ground can be dug effectively by a tilted or angled
blade.
If the ground is harder, use a ripper attachment for better efficiency.

FELLING TREES, REMOVING STUMPS

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

For trees with a diameter of 10 to 30 cm (3.9 to 11.8 in), raise the

blade high and push 2 or 3 times to fell the tree.
Next, travel in reverse, and dig the corner of the blade into the
ground to cut and dig up the roots.
When doing this, never hit the tree at high speed or apply shock to
fell the tree.

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OPERATION OPERATION

PUSHER OPERATIONS
When carrying out pusher operations, always install a pusher
plate.
When approaching the other machine, depress the decelerator
pedal to reduce the engine speed and approach slowly. After
coming into contact, raise the travel speed slowly and push with
full power.
If the pivot turns switch is kept at the ON position, it is possible
to carry out pivot turns, and this improves the ease of pusher
operation.

SMOOTHING

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

When finishing the ground surface to a smooth finish after digging

or filling operations, keep a full load of soil in the blade and operate
the blade up or down in small movements while traveling forward.
When leveling windrows or ruts left by the tracks, set the blade to
the FLOAT position, travel at low speed in reverse and drag the
blade over the ground surface.

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OPERATION OPERATION

EFFECTIVE USE OF MODE SELECTION SYSTEM

(1) Lock up mode switch (3) Reverse slow mode selector switch
(2) Economy mode selector switch

Selecting mode to match the type of work and quality of rock and soil makes to perform operations effectively.
For the machine that is solely used for crushed rocks, it can be done that when the ignition switch is turned ON, all
mode switches are turned ON. Contact your Komatsu distributor for such modification of the switches.
When all the mode selection switches are off, the selection is suitable for conventional digging and dozing of
bedrock.
The condition when all the mode selection switches are off is called the standard mode.
Only the reverse slow mode can be selected in combination with the lock-up mode.
The economy mode, and reverse slow mode can be used independently or in combination.

Dozing
Reverse slow mode
Lock up mode Economy mode
{ {
{ {

{: Possible to use : Compound use not possible

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OPERATION OPERATION

SELECTION OF MODE

DOZING OPERATIONS

LOCK UP MODE
By using the lock up mode, the travel speed increases, the
operating efficiency is improved, and the fuel consumption is also
reduced.
Speed ranges that can be used: All speed ranges
Applicable operations: Dozing loose material (suitable for
long-distance hauling operations)
When the lock up mode is turned ON, direct drive or torque
converter drive are automatically selected according to the load.

(Example)
Slot dozing operations

Hillside dozing operations

REMARK
If dozing operations power carried out on a slope of an angle of
more than 15°, the lock up may easily be canceled, so
operations are easier to carry out in the standard mode.
For normal ripping operations, if the lock up mode is used, the
lock up will repeatedly switch between ON and OFF, so use the
standard mode.
Even with ripping operations, if the ground is extremely soft, the
lock up mode can be used.

(1)Quality of earth and sand

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OPERATION OPERATION

ECONOMY MODE
Using the economy mode makes it possible to reduce wasteful
shoe slippage and to reduce the fuel consumption.
Speed ranges that can be used: F1
Applicable operations: Hauling after ripping, dozing blasted
rock, smoothing.

When the economy mode is turned ON, it is automatically set to [1].

Carry out dozing operations in this condition, then set to [2] and carry out operations. From this test, select the
matching that gives power and low shoe slip ratio (frequency of deceleration operation).
Mode [1] is set to approx. 90% of full power and mode [2] is set to approx 70%.
(Example)
Fine leveling operations

Ripping and dozing operations

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OPERATION OPERATION

REVERSE SLOW MODE

This reduces the travel speed when traveling in reverse, reduces
the frequency of operating the decelerator pedal, and improves the
riding comfort for the operator.
Speed ranges that can be used: R1, 2, 3
Applicable operations: Travelling on bedrock

Use this mode to reduce the travel speed when traveling in R1, R2, or R3.
When the reverse slow mode is ON, the travel speed is set to approx. 80% of the full travel speed.
Use this mode to reduce the travel speed when traveling in reverse after ripping and dozing bedrock or when
traveling in reverse after dozing on steep slopes. The travel speed differs in each mode according to whether it is
used in combination with the economy mode.
When traveling on bedrock, if it is felt that the travel speed when
traveling in reverse is too high, turn the reverse slow mode ON.
This will reduce the travel speed when traveling in reverse.

When traveling down slopes, if it is felt that the travel speed when
traveling in reverse is too high, turn the reverse slow mode ON.
This will reduce the travel speed when traveling in reverse.

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OPERATION OPERATION

PROCEDURE FOR SELECTING MODE ACCORDING TO NATURE OR NEEDS TO WORK

Use the table below to select the mode that matches the nature or needs of the operation.

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OPERATION OPERATION

RIPPER OPERATION

EFFECTIVE METHOD OF USE

The optimum digging angle for the shank is when the shank is
perpendicular to the ground (ripping angle: 45° to 50°).
In comparatively soft rock (seismic velocity: 1500 m/s or below),
it is also possible to carry out ripping with the shank tilted to the
rear.

On comparatively hard rock, if ripping is carried out with the

shank tilted to the rear, there will be excessive wear of the point
of tip (1), and the self-sharpening ability will be lost.
During ripping operations, if the shoes slip because of boulders
or resistance from the bedrock, use the tilt cylinder.
When picking up a stone, advance the machine at a fixed gear
speed (F1 or F2).

REMARK
When raising boulders or digging up rockbed, do not put the transmission in neutral. If the transmission is in
neutral, the reaction of the tilt cylinder will push the machine back. Always operate the machine with the
transmission in FORWARD.
Choosing a suitable ripper point to match the type of rock is one of the most important elements in using the ripper
effectively.
Ripper points are available for different types of rock, so select the most suitable ripper point from the list. For
details, see "PROCEDURE FOR SELECTING RIPPER POINT (PAGE 6-4)".

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OPERATION OPERATION

DIGGING UP BOULDERS OR ROCKBED

During ripper operations, if stubborn boulders or rockbed cause the
travel speed to become slower, operate the tilt cylinder to dig up
the boulder/rockbed.

OPERATING ON SLOPES
When using the variable ripper, adjust the length of the tilt cylinder
to select dimension L.

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OPERATION OPERATION

METHOD OF OPERATING PIN PULLER

1. Stop the machine in a safe place and lower the shank to the
ground.
2. Operate the pin puller controller switch to the "PULL OUT"
position (1) and remove the mounting pin.

(F)Front of the machine

3. Move the ripper up or down to set to the desired shank position.

REMARK
Align mark of ripper (A) with top surface of holder (B).

(C)Depth Max.
(D)Depth intermediate
(E)Depth min.

4. Operate the pin puller control switch to insert the mounting pin.
If the pin does not match the position of the hole in the shank,
set the pin puller control switch to the "PUSH IN" position (2)
and slowly move the ripper up or down.

REMARK
When raising the pin position to increase the digging depth, use a
long protector to prevent wear of the shank.

(F)Front of the machine

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OPERATION OPERATION

OPERATING METHOD FOR RIPPING OPERATIONS

BASIC OPERATING METHOD

(1) Point in contact with ground

(2) Insert point to specified depth
(3) Ripping
(4) Start raising ripper
(5) Shank tilted back
(6) Start lowering ripper

TRACK OF RIPPER SHANK

Carry out the ripping operation as follows, passing through the points shown in the diagram above.
(1) Tilt the ripper back, lower the ripper point to the ground that the place to begin ripping, and raise the rear of the
machine.
(2) To press the decelerator pedal and lower the engine speed, set the speed range to F1, and tilt the ripper to insert
the point to the specified depth.
(3) When the ripper point reaches the specified depth, raise the engine speed to full speed and travel forward.
Tilt the shank and carry out ripping.
If the circuit is relieved even when the shank is tilted, change the shank mounting hole to the hole below and
reduce the ripping depth.
(4) After completing the ripping, travel forward, raise the shank from the bed rock, then travel in reverse.
(5) While traveling in reverse, tilt the ripper back, and when the starting point for the ripping is reached, lower the
ripper.

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OPERATION OPERATION

REMARK
If the ripper is applied with the rear of the machine raised from
the ground, the drawbar pull will be low, so the ripping efficiency
will be reduced.
If the ripping depth is kept constant, there will be no
unevenness, and this will increase the efficiency of the dozing
operation.

(A)Length of track on ground

RIPPING BY CLIFFS
When carrying out ripping at the edge of a cliff, tilt the ripper back
(B) to make depth (L) longer.

Depress the decelerator pedal, drive slowly forward, and when

the ripper point contacts the cliff, tilt the ripper in (A).

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OPERATION OPERATION

RIPPING BY SLOPE FACES

(Giant ripper)
When carrying out ripping work at the edge of slope faces, make
the ripper tilt back (B) angle small, and if there is an area where
the slope face (1) has not been ripped, apply the ripper
diagonally.

REMARK
In the case of the multi-shank ripper, carry out ripping at right
angles to the slope face.

(B)Tilt back (MAX)

(1)Slope face
(2)Ripping base

Cross ripping
On jobsites with hard bedrock, for rocks and boulders which are
impossible to break or dig up with one ripping pass, carry out the
second ripping pass at right angles to the first ripping direction.
At the edge of cliffs, where it is impossible to apply the ripper in
a cross direction, make the space between the shanks smaller
and carry out ripping.

During the ripping operation, if there is any hard bedrock, carry

out ripping in the opposite direction to the direction where the
ripper was applied. If it is still impossible to break up the rock,
break up the area around the bedrock a little at the time.
When carrying out concentrated ripping of hard bedrock, the
work efficiency is high if the ripper is applied to the whole of the
digging face.

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OPERATION OPERATION

DIGGING UP BOULDERS
During the ripping operation, if boulders are found which are difficult to break and shoe slippage occurs, dig up the
boulder as follows.
1. Depress the decelerator pedal and lower the engine speed to
a point where there is no shoe slippage.

2. Operate the ripper lever to the TILT position and carry out
ripping and digging.

3. If there are boulders which are impossible to break or dig up

with the tilt operation, move forward slightly and tilt the shank
back, then operate the tilt again and dig up the boulder.

4. Even when the operation in Step 3 is repeated, if it is

impossible to break or dig up the boulder, drive back about 10
cm, raise the shank, avoid the rock or boulder that cannot be
ripped, then drive forward and start ripping again.

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OPERATION OPERATION

PRECAUTIONS WHEN RIPPING

For the digging angle when ripping, set so that the top of the
shank is perpendicular, then lower the ripper.
Do not carry out ripping for long periods with the shank tilted
back. The tip of the point will wear to a round shape.

Do not change the direction of travel during the ripping

operation. This will cause breakage of the shank. When
changing the direction of travel, remove the shanks from the
ground before turning.

Never drive in reverse when the ripper point is inserted in the

bedrock. The pin installing the point (1) will break and the point
will fall off.
Stop the machine, tilt back (B) slightly, then raise the ripper
slowly.

After ripping, if the broken rock is comparatively large, avoid

traveling over the ripping path (2) when traveling in reverse.
When traveling in reverse (3), check the rear carefully to avoid
heating any large rocks. As far as possible, choose level ground
to travel over.

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OPERATION OPERATION

ADJUSTING POSTURE OF WORK EQUIPMENT

WARNING
When adjusting, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop
the engine and lock the work equipment securely with the work equipment lock lever.

BLADE ADJUSTMENT

TILTING THE TILTDOZER

NOTICE
The maximum tilt is 1000 mm (39.4 in).
Adjust the tilt so that it does not exceed the limit of 1000 mm (39.4 in).
If the maximum tilt is exceeded, excessive force will be brought to bear on all parts, and this will damage the machine.

If it is necessary to have a larger tilt amount than can be obtained

by operating the blade control lever, do as follows.
Use bar handle (2) installed to the left brace to rotate brace (1) and
change brace length ( l ). This makes it possible to obtain a
maximum tilt of 1000 mm.
The standard distance between the joints ( l ) is as follows.
Sigmadozer: 1403 mm
Semi U-dozer,U-dozer: 1460 mm

ADJUSTING SHIM IN BLADE CYLINDER CAP

Set the standard shim adjustment in the blade cylinder cap to 4 mm
(0.16 in).
Remove shims to balance the wear of the cap and the ball at the
end of the piston rod.
The proper clearance to be maintained with the shims is 0.2 to 0.5
mm (0.008 to 0.02 in).

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OPERATION OPERATION

ADJUSTING BRACE
(Machine equipped with single tiltdozer)

WARNING
If maintenance is carried out with the engine running, always have one worker sitting in the operator's seat while another worker
carries out the maintenance. Both workers must mutually confirm the safety during the operation.

Adjustment can be carried out more easily if the engine is started,

the inching operation used to carry out tilting to the left and right,
and the blade shaken up and down while turning the brace handle
(1).

When extending the brace

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

REMARK
When operated in this way, the blade is tilted, so the handle gradually becomes heavier. When this happens, return
the blade from the tilt position to the horizontal position and turn the handle again according to the procedure given
above.

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OPERATION OPERATION

SHIM ADJUSTMENT (In case of Sigmadozer)

Adjust with shims so that the play in the axial direction (direction of
the arrow) at the ball joints (3 places) is within 1 mm (0.039 in).

1. Remove shim (1) and tighten bolts (2) to eliminate the ball joint
play.
2. Measure clearance "A" and remove bolts (2).
3. Install shim (1) having its thickness of "A" mm to "A + 1" mm
("A" in. to "A + 0.04" in) in place with bolts 2.
4. Confirm that ball joint can move smoothly after tightening bolts.

SHIM ADJUSTMENT (In case of Semi U-dozer, U-dozer)

Adjust the thickness of shim so that the ball joint play (4 places) in
the axial direction (shown by the arrow) does not exceed 1 mm
(0.04 in).

1. Remove shim (1) and tighten bolts (2) to eliminate the ball joint
play.
2. Measure clearance "A" and remove bolts (2).
3. Install shim (1) having its thickness of "A" mm to "A + 1" mm
("A" in. to "A + 0.04" in) in place with bolts 2.
4. Confirm that ball joint can move smoothly after tightening bolts.

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OPERATION OPERATION

ADJUSTING RIPPER

ADJUSTING DIGGING DEPTH

There are mounting holes in the shank to chose to match the ripping depth. Normally, use the bottom hole, but if
particularly deep ripping is needed, use the top hole.
When a giant ripper is installed, use the pin puller.
For details, see "METHOD OF OPERATING PIN PULLER (PAGE 3-131)".

(Machines equipped with multi-shank ripper)

1. Place a pointed object on the tip of pin (1), then hit with a
hammer to remove from the opposite side.
2. Remove pin (2) and change the position of the shank hole.
3. Insert pin (1) partially by hand then knock it in with a hammer.
The pin is made of one piece, so insert it partially by hand
then knock it in with a hammer.

REPLACING POINT AND PROTECTOR

To protect the shank, if the protector and point installed to the tip
are worn, replace them.
Place a pin remover on the pin marked by the arrow, then hit with
a hammer to remove from the opposite side.

REMARK
The pin is a unitized type, so insert the pin partially by hand, then
knock it in fully with a hammer.

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OPERATION OPERATION

TIPS FOR LONGER UNDERCARRIAGE LIFE

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

OPERATION METHOD
Select the track shoe that best suits the type of soil to be encountered in service.
Consult your Komatsu distributor when selecting track shoes.
Do not allow shoe slipage to occur during operation. If slipage occurs, reduce load to the blade until slipping stops.
Avoid sudden starts, acceleration or stops, unnecessary high speeds and sharp turns.
Always operate machine in a straight line whenever possible. When making turns, be careful not to allow the
machine to stay to one side, so operation in both turning directions can be done properly. Make turns with the
largest possible radius.
Prior to operation, clear boulders and obstacles to prevent machine from riding over them while operating.
On a slope, operate the machine parallel to the inclination of the
slope. Do not operate across the slope. Also when stopping the
machine on a slope, the machine should face the top of the
slope.
When ground inclines to the left or right during digging
operations, do not continue to dig with the incline. Move the
machine back to level ground and start to dig again.
Do not force the machine to carry out work that exceeds its
working capability. Such work includes cases where the idler or
sprocket come off the ground when the machine meets
obstacles that resist the power of the machine during dozing or
ripping operations.

INSPECTION AND ADJUSTING

Properly adjust track tension.
Tension should be measured at clearance (A) shown in the
diagram - usually 20 to 30 mm (0.8 to 1.2 in) at this point. For
rocky terrain, tighten tracks slightly. In clay or sandy areas,
slightly loosen them. (For inspection and adjustment
procedures, refer to "CHECK AND ADJUST TRACK TENSION
(PAGE 4-30)").
Check idler rollers for oil leakage as well as for loose bolts and
nuts. If any trouble is detected, repair immediately.

Check the clearance between the idler guide plate (1) and the
track frame. If clearance (B) increases, idler may develop side
motion and tracks may come off. (For inspection and adjustment
procedures, refer to "ADJUST IDLER CLEARANCE (PAGE
4-34)".

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OPERATION OPERATION

INSPECTION AND REPAIR

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

MEASURING HEIGHT OF GROUSER

After taking up slack in track shoes, measure height at center of
shoe as shown below.
Standard height (h): 88 mm (3.5 in)
Repair limits: 30 mm (1.2 in)

MEASURING OUTSIDE DIAMETER OF TRACK ROLLER

1. Measure height (size C) of link tread as shown.
2. Stop machine at position where link tread, whose size C has
been measured completely, contacts roller tread. Then
measure size B.
3. Calculate outside diameter of tread (size A)
A = (B - C) x 2
Standard size (A): 255 mm (10.0 in)
Repair limits: 185 mm (7.3 in) (Single roller)
195 mm (7.7 in) (Double roller)

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OPERATION TRANSPORTATION

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

TRANSPORTATION PROCEDURE
When transporting the machine, choose the optimum transportation method in reference to the weight and
dimensions shown in "SPECIFICATIONS (PAGE 5-2)". Note that machine specifications (weight and dimensions)
vary depending on the kind of track shoes and work equipment.

LOADING, UNLOADING WORK

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

When loading or unloading, always use ramps or a platform and carry out the operations as follows.

LOADING
1. Load and unload on firm level ground only.
Maintain a safe distance from the edge of a road.
2. Apply the trailer brakes securely, then put blocks (1) under the
tires to prevent the trailer from moving.
Set left and right ramps (2) parallel to each other and
equally spaced to the left and right of center (3) of the trailer.
Make angle of installation (4) a maximum of 15°. If the
ramps bend a large amount under the weight of the
machine, put blocks under the ramps to prevent them from
bending.

3. Set parking brake lever to the FREE position (F).

4. Set the transmission in the 1st gear and run the engine at low
idle.
5. Set the travel direction toward the ramps and drive slowly.
6. The center of gravity of the machine shifts suddenly at the
border between the ramps and trailer, and the machine is
unbalanced and becomes dangerous. Accordingly, pass the
border slowly.
7. Stop the machine at the specified position on the trailer.

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TRANSPORTATION OPERATION

SECURING MACHINE

NOTICE
Stow the antenna away.

Load the machine onto a trailer as follows:

1. Lower the work equipment slowly.
(When transporting with work equipment installed)
2. Set the work equipment lock lever to the LOCK position (L)
securely.
(When transporting with work equipment installed)

3. Set the parking brake lever to the LOCK position (L) securely.
4. Stop the engine, then remove the key from the starting switch.

5. Place blocks under both ends of the tracks to prevent the

machine from moving during transportation, and secure the
machine with chains or wire rope of suitable strength.
Be particulary careful to secure the machine in position so it
does not slip to the side.

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.

OPERATION TRANSPORTATION

UNLOADING
1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road.
2. Apply the trailer brakes securely, then put blocks (1) under the
tires to prevent the trailer from moving.
Set left and right ramps (2) parallel to each other and
equally spaced to the left and right of center (3) of the trailer.
Make angle of installation (4) a maximum of 15°. If the
ramps bend a large amount under the weight of the
machine, put blocks under the ramps to prevent them from
bending.

3. Remove the chains and wire ropes fastening the machine.

4. Start the engine.
Warm the engine up fully.
5. Set main work equipment lock lever to FREE position (F), and
raise the work equipment.
(When transporting with work equipment installed)

6. Set parking brake lever to the FREE position (F).

7. Set the transmission in the 1st gear and run the engine at low
idle.

8. Set the travel direction toward the ramps and drive slowly.
9. The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and the
machine is unbalanced and becomes dangerous. Accordingly, pass the border slowly.
10. Drive down the ramps slowly and carefully until the machine leaves the ramps perfectly.

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TRANSPORTATION OPERATION

METHOD OF LIFTING MACHINE

WARNING
The operator carrying out the lifting operation using a crane must be a properly qualified crane operator.
Never raise the machine with any worker on it.
Always make sure that the wire rope is of ample strength for the weight of this machine.
When lifting, keep the machine horizontal.
When carrying out lifting operations, set the work equipment lock lever and parking brake lever to the LOCK position to prevent
the machine from moving unexpectedly.
Never enter the area under or around a raised machine.
Never try to lift the machine in any posture other than the posture given in the procedure below or using lifting equipment other
than in the procedure below.
There is a hazard that the machine may lose its balance.

NOTICE
This method of lifting applies to the standard specification machine.
The method of lifting differs according to the attachments and options installed.
For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor.

When lifting the machine, stop it on a level place, then observe the following procedure.
1. Set the work equipment lock lever to the LOCK position (L)
securely.

2. Set the parking brake lever to the LOCK position (L) securely.
3. Stop the engine.

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OPERATION TRANSPORTATION

NOTICE
Use protectors to prevent the wire rope from being cut on sharp corners
and to prevent the wire rope from cutting into the machine bodywork.
When using a spreader bar, select an ample width to prevent contact
with the machine.

4. Install wire ropes, slings, etc. matched to the weight of the

machine to the lifting points as shown in the diagram on the
right.
5. After setting the wire ropes, lift up the machine and stop at 100
to 200 mm (3.9 to 7.9 in) above the ground, and check that the
wire ropes are not slack and the machine is level, then lift up
slowly.

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

REMARK
Note that the asphalt road becomes soft in summer.

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TRANSPORTATION OPERATION

REMOVAL OF CAB
(Machine equipped with cab) (If equipped)
If it is necessary to remove the cab for transportation, disconnect
the washer hoses, cab wiring, and washer motor wiring before
removing the cab.
1. Pull the grommet portion in towards the cab from the hole in the
machine cover, then remove.

2. Disconnect 4 washer hoses and the wiring (single wires x 2,

4-pin plug x 1) from the socket.
After removing, cover the washer hoses with a vinyl bag to
prevent any dirt or dust from entering.
Before removing the cab, measure the clearance between
the cab and each lever (joystick and blade control lever,
etc.). Note the measurements to use as a standard when
installing the cab again.

INSTALLATION OF CAB
(Machine equipped with cab) (If equipped)
Install the cab parts in the opposite order to removal.
Connect all parts that were disconnected.
1. Lower the cab slowly on top of the floor frame.
2. Align the cab with the floor frame, then install bolts and
washers in holes (A) - (U).
Do not screw the bolts in fully. Screw them in 3 or 4 turns.
3. Tighten the bolts in holes (N) - (U) fully.
Tighten in the order (N), (U), (Q), (R), (O), (T), (P), (S).
4. Tighten the bolts, (A) to (M), completely.

If there are any unclear points about removing or installing the

cab, please contact your Komatsu distributor.

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.

OPERATION COLD WEATHER OPERATION

COLD WEATHER OPERATION

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

FUEL AND LUBRICANTS

Change to oil with low viscosity for all components. For details of the specified visicosity, see "RECOMMENDED
FUEL, COOLANT, AND LUBRICANT (PAGE 4-13)".

COOLANT
WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash
it off with large amounts of fresh water and see a doctor at once.
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator,
please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.

NOTICE
Please use Komatsu genuine supercoolant (AF-NAC) for the coolant. As a basic rule, we do not recommend the use of any coolant
other than Komatsu genuine supercoolant.

The Supercoolant is already diluted with distilled water, so it is not flammable.

For details of the density of the Supercoolant and the interval for changing the coolant, see "CLEAN INSIDE OF
COOLING SYSTEM (PAGE 4-22)".

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.

COLD WEATHER OPERATION OPERATION

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

When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the
battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%. Insulate it against cold
temperature to ensure the machine can be started easily the next morning.

REMARK
Measure the specific gravity and calculate the charging rate from the following conversion table.

Electrolyte
Temperature 20°C 0°C -10°C -20°C
Charging (68°F) (32°F) (14°F) (-4°F)
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
As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine, store
the battery in a warm place, and install it again the next morning.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after the
day's work to prevent diluted electrolyte in the battery from freezing during the night.

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OPERATION COLD WEATHER OPERATION

AFTER COMPLETION OF WORK

WARNING
Performing idle-running 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.
Park the machine on hard, 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 be moved the next morning.
Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
Fill the fuel tank to capacity. This minimizes moisture condensation in the tank when the temperature drops.

AFTER COLD WEATHER

When the season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all parts with oil of the viscosity specified.
For details, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-13)".
When it is unnecessary to use the automatic starting aid (APS) (When the ambient temperature is above 15°C
(59°F)), Always keep the fuel valve closed.

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.

LONG-TERM STORAGE OPERATION

LONG-TERM STORAGE
BEFORE STORAGE
When keeping in long-term storage (more than one month), store as follows.
Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level
ground and cover the machine with canvas.
Completely fill the fuel tank. This prevents moisture from collecting.
Lubricate and change the oil before storage.
Apply a thin coat of grease to metal surface of the hydraulic piston rods and the idler adjusting rods.
Disconnect the negative terminals of the battery and cover it, or remove it from the machine and store it
separately.
Place all control levers at the neutral position, set the work equipment lock lever and parking brake lever to the
lock
position, and set the fuel control dial to the low idling position.
To prevent rust, fill with Komatsu genuine supercoolant (AF-NAC) to give a density of at least 30% for the engine
coolant.

DURING STORAGE
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, also charge the battery.
For machines equipped with an air conditioner, run the air conditioner.

AFTER STORAGE

NOTICE
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor
before using it.

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

STARTING MACHINE AFTER LONG-TERM STORAGE

When starting the engine after the machine has been in storage for a long period, carry out the warming-up operation
thoroughly. For details, see the procedure in "WARMING UP OPERATIONS (PAGE 3-101)".

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OPERATION TROUBLESHOOTING

TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
When starting the engine again after running out of fuel, fill with fuel, then bleed the air from the fuel system before
starting the engine.
Always watch the fuel level and be careful not to run out of fuel.
If the engine has stopped because of lack of fuel, it is necessary to use the priming pump to bleed the air completely
from the fuel circuit.

PROCEDURE FOR BLEEDING AIR

CAUTION
The fuel injection pump and nozzle of this engine consist of more precise parts than the conventional ones. If foreign matter
enters them, it can cause a trouble. Accordingly, if dust sticks to the fuel system, wash it off with clean fuel.
When opening the air bleeding plug at the fuel filter head, take care. Fuel may spout because of residual pressure.

1. Loosen air bleed plug (A) at the fuel main filter head (1).

NOTICE
Do not loosen the plug of the fuel pre-filter head. This is at the suction end,
so if it is loosened, it will be impossible to bleed the air.

2. Loosen the wing nut of priming pump (2), carry out pumping to
pump out the bubbles from air bleed plug (A), and check that
fuel comes out.

3. Tighten the air bleed plug (A).

Tightening torque: 2.0 to 3.9 Nm {0.2 to 0.4 kgm}

4. Tighten the butterfly nut of the lever of priming pump (2).

5. Turn the key in the starting switch to the START position and
start the engine.
When doing this, do not crank the starting motor continuously
for more than 20 seconds. If the engine does not start, wait for
at least 2 minutes, then try again. Perform this operation a
maximum of 4 times.

6. If the engine does not start, repeat the operation from Step 1.

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TROUBLESHOOTING OPERATION

METHOD OF TOWING MACHINE

WARNING
Serious injury or death could result if a disabled machine is towed
incorrectly or if there is a mistake in the selection or inspection of the wire
rope.
Always check that the wire rope used for towing has ample strength for
the weight of the machine being towed.
Never use a wire rope which has cut strands (A), reduced diameter (B),
or kinks (C). There is danger that the rope may break during the towing
operation.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing machine
and the machine being towed.
Operate the machine slowly and be careful not to apply any sudden load
to the wire rope.

NOTICE
The max. allowable drawbar pull of this machine is 367,750 N (37,500 kg). Do not attempt to pull anything beyond this limit.

If the machine is stuck in mud and cannot escape under its own
power, or when towing a heavy object, fit wire to the towing hook
as shown in the diagram on the right, or if the machine is
equipped with a counterweight, fit the wire to the towing hook on
the counterweight and tow the machine.

When towing a machine, travel at a speed of less than 1 km/h for

a distance of only a few meters to a place that is suitable for
carrying out repairs.
This is for use only in emergencies.

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OPERATION TROUBLESHOOTING

IF BATTERY IS DISCHARGED
WARNING
It is dangerous to charge a battery when mounted on a machine. Make
sure that it is dismounted before charging.
When checking or handling the battery, stop the engine and turn the
starting switch key to the OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion.
Do not bring lighted cigarettes near the battery, or do anything that will
cause sparks.
Battery electrolyte is dilute sulfuric 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 water. If it gets in your eyes, wash it out with
fresh water and consult a doctor.
When handling batteries, always wear safety glasses and rubber
gloves.
When removing the battery, first disconnect the cable from the ground
(normally the negative (-) terminal). When installing, install the positive
(+) terminal first.
If a tool touches the positive terminal and the chassis, there is danger
that it will cause a spark, so be extremely careful.
(A)When removing, disconnect the cable
If the terminals are loose, there is danger that the defective contact may
from the ground terminal first.
generate sparks that will cause an explosion.
(B)When installing, connect the cable to
When removing or installing the terminals, check which is the positive
the positive(+) terminal first.
(+) terminal and which is the negative (-) terminal.

REMOVAL AND INSTALLATION OF BATTERY

Before removing the battery, remove the ground cable (normally connected to the negative (-) terminal).
If any tool touches between the positive terminal and the chassis, there is a hazard of sparks being generated.
When installing the battery, connect the ground cable last.
When replacing the battery, secure it with battery hold-down.
Tightening torque:Tightening battery terminal: 9.8 to 14.7 Nm (1 to 1.5 kgm, 7.2 to 10.8 lbft)

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.

TROUBLESHOOTING OPERATION

REMOVAL, INSTALLATION OF BATTERY CABLE

1. Open battery cover (1), (2).
2. Before removing the battery, remove the ground cable
(normally connected to the negative (-) terminal). If any tool
touches between the positive terminal and the chassis, there is
danger of sparks being generated. Loosen the nut of the
terminal and remove the wires from the battery.

3. When installing the battery, connect the ground cable last.

Insert the hole of the terminal on the battery and tighten the nut.
Tightening torque: 9.8 to 19.6 Nm (1 to 2 kgm, 7.2 to 14.5 lbft)
4. Close battery cover (1), (2).

PRECAUTIONS WHEN CHARGING BATTERY

When the charging the battery, if the battery is mistakenly handled,
there is danger of explosion. Follow the precautions in "IF
BATTERY IS DISCHARGED (PAGE 3-155)" and the instructions
given in the charger manual, and always do as follows.
Set the voltage of the charger to match the voltage of the battery
to be charged. If the correct voltage is not selected, the charger
may overheat and cause an explosion.
Connect the positive (+) charger clip of the charger to the
positive (+) terminal of the battery, then connect the negative (-)
charger clip of the charger to the negative (-) terminal of the
battery. Be sure to attach the clips securely.

STARTING ENGINE WITH BOOSTER CABLE

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

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OPERATION TROUBLESHOOTING

PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE

WARNING
When connecting the cables, never contact the positive (+) and negative
(-) terminals.
When starting the engine with a booster cable, wear safety glasses and
rubber gloves.
Be careful not to let the normal machine and problem machine contact
each other. This prevents sparks from generating near the battery which
could ignite the hydrogen gas given off by the battery.
Make sure that there is no mistake in the booster cable connections.
The final connection is to the engine block of the problem machine, but
sparks will be generated when this is done, so connect to a place as far
as possible from the battery.
When disconnecting the booster cable, take care not to bring the clips
in contact with each other or with the machine body.

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

CONNECTING THE BOOSTER CABLES

Keep the starting switch of the normal machine and problem machine in the OFF position.
Connect the booster cable as follows, in the order of the numbers marked in the diagram.
1. Connect the clip of booster cable (A) to the positive (+) terminal
of battery (C) on the problem machine.
2. Connect the clip at the other end of booster cable (A) to the
positive (+) terminal of battery (D) on the normal machine.
3. Connect the clip of booster cable (B) to the negative (-) terminal
of battery (D) on the normal machine.
4. Connect the clip at the other end of booster cable (B) to engine
block (E) on the problem machine.

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TROUBLESHOOTING OPERATION

STARTING THE ENGINE

WARNING
Always check that the work equipment lock lever is set to the LOCK position, regardless of whether the machine is working
normally or has failed. Check also that all the control levers are in the HOLD or NEUTRAL position.

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

DISCONNECTING THE BOOSTER CABLES

After the engine has started, disconnect the booster cables in the reverse of the order in which they were connected.
1. Remove the clip of booster cable (B) from engine block (E) on
the problem machine.
2. Remove the clip of booster cable (B) from the negative (-)
terminal of battery (D) on the normal machine.
3. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (D) on the normal machine.
4. Remove the clip of booster cable (A) from the positive (+)
terminal of battery (C) on the problem machine.

3 - 158
.

OPERATION TROUBLESHOOTING

OTHER TROUBLE

ELECTRICAL SYSTEM
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.

Problem Main cause Remedy

Lamp does not glow brightly even Defective wiring ( Check, repair loose terminals,
when the engine runs at high speed disconnections
Check fuses and diodes in fuse
box)
Lamp flickers while engine is Defective adjustment of fan belt Adjust fan belt tension
running tension For details, see EVERY 250
HOURS SERVICE
Charge lamp does not go out even Defective alternator ( Replace)
when engine is running Defective wiring ( Check, repair
Check fuse, diode in fuse box)
Abnormal noise is generated from Defective alternator ( Replace)
alternator
Starting motor does not crank Defective wiring ( Check, repair)
when starting switch is turned ON Insufficient battery charge Charge
Pinion of starting motor keeps Insufficient battery charge Charge
going in and out
Starting motor turns engine Insufficient battery charge Charge
sluggishly Defective starting motor ( Replace)
Starting motor disengages before Defective wiring ( Check, repair)
engine starts Insufficient battery charge Charge
Engine pre-heating monitor lamp Defective wiring ( Check, repair)
does not light up Defective timer ( Replace)
(When the temperature of the Defective monitor ( Replace)
engine coolant exceed 20°C Disconnection in glow plug ( Replace)
(68°F), this condition is normal)
Air conditioner operation is Blown fuse ( Check, repair)
defective Insufficient battery charge Charge
Defective air conditioner switch ( Replace air conditioner switch)
Defective blower switch ( Replace blower switch)
Defective compressor ( Replace)
Blade does not pitch when pitch Defective wiring ( Check, repair)
operation is carried out (dual tilt Defective switch ( Replace)
specification machine only) Defective solenoid valve ( Replace)

3 - 159
.

TROUBLESHOOTING OPERATION

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

Abnormality Method of displaying

Abnormality Remedy
code abnormality
E01 Lock up torque converter does Abnormality code and The automatic functions stop and
not come ON service hour are some functions stop, but it is still
Dual tilt does not work displayed in turn on possible to carry out operations.
service meter portion Please contact your Komatsu
distributor immediately for repairs.
E02 Tilt limit does not work Abnormality code and If user stops engine and then
Does not shift up or shift down service hour are starts again, operations are
Pitch does not work displayed in turn on possible without limit functions.
service meter portion, However, user must be careful.
caution lamp flashes, Please contact your Komatsu
buzzer sounds distributor immediately for repairs.
E03+CALL Number of speed ranges that Abnormality code and Move machine to a safe place,
can be used is limited service hour are then contact your Komatsu
Engine does not run at full displayed in turn on distributor immediately for repairs.
speed service meter portion,
Excessive shock when shifting caution lamp flashes,
gear buzzer sounds
Turning ability becomes poor
Excessive braking shock
Abnormal engine coolant
temperature sensor
E04+CALL Engine control impossible Abnormality code and Stop machine, then contact your
Travel impossible service hour are Komatsu distributor immediately
Machine does not stop displayed in turn on for repairs.
service meter portion,
caution lamp flashes,
buzzer sounds

3 - 160
.

OPERATION TROUBLESHOOTING

CHASSIS
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.

Problem Main causes Remedy

Improper tightening of oil pipe, Check, repair

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

Clogged radiator Clean radiator core

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

Torque converter oil temperature Defective oil temperature gauge ( Replace oil temperature gauge)
gauge dose not work Defective contact in wiring ( Check, repair)

Lack of engine horsepower See ENGINE related parts

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

Insufficient oil inb power train Add oil to specified level.For

case details, see CHECK BEFORE
STARTING
Machine will not move off when Transmission oil pressure does Go to oil pressure in torque
joystick is placed at FORWARD not rise converter fails to rise
Defective lever wiring ( Check, repair)
Parking brake lever is at LOCK Set to FREE position
position

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

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

Machine doesn't stop when brake Defective brake adjustment ( Adjust linkage. Check brake
pedal are depressed pressure)
Track is too losse Adjust track tension.For details,
Track comes off
see WHEN REQUIRED
Track is too loose or too tight Adjust track tension. For details,
Sprocket develops abnormal wear
see WHEN REQUIRED

3 - 161
.

TROUBLESHOOTING OPERATION

Problem Main causes Remedy

Machine does not travel in straight Defective adjustment of HSS ( Adjust, replace)
line controller

Lack of hydraulic oil Add oil to specified level. For

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

Lack of hydraulic oil Add oil to specified level.For

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

Insufficient force of ripper Leakage from piping ( Tighten)

3 - 162
.

OPERATION TROUBLESHOOTING

ENGINE
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.

Problem Main causes Remedy

Engine oil pan oil level is low Add oil to specified level, see
(sucking in air) CHECK BEFORE STARTING
Clogged oil filter cartridge Replace cartridge, see EVERY
Engine oil pressure monitor flashes
500 HOURS SERVICE
when engine speed is raised after
Defective tightening of oil pipe ( Check, repair)
completion of warm-up
joint, oil leakage from damaged
part
Defective monitor panel ( Replace)
Coolant level low, water leakage Add coolant, repair, see
CHECK BEFORE STARTING
Steam is emitted from top part of Dirt or scale accumulated in Change coolant, clean
radiator (pressure valve) cooling system inside of cooling system, see
WHEN REQUIRED
Clogged radiator fins or Clean or repair, see WHEN
damaged fins REQUIRED
Defective thermostat ( Replace thermostat)
Engine water temperature monitor Loose radiator filler cap (high Tighten cap or replace packing
remains alight altitude operation) altitude operation)
Defective monitor panel ( Replace)
Lack of fuel Add fuel, see CHECK BEFORE
STARTING
Air in fuel system Repair place where air is sucked
Engine does not start when starting in
motor is turned No fuel in fuel filter ( Replace pump or nozzle)
Starting motor cranks engine See ELECTRICAL SYSTEM
sluggishly
Defective valve compression ( Adjust valve clearance)
Too much oil in oil pan Add oil to specified level, see
Exhaust gas is white or blue CHECK BEFORE STARTING
Improper fuel Change to specified fuel
Clogged air cleaner element Clean or replace, see WHEN
REQUIRED
Exhaust gas occasionally turns
Defective nozzle ( Replace nozzle)
black
Defective compression ( Adjust valve clearance)
Defective turbocharger ( Clean or replace, turbocharger)
Combustion noise occasionally Defective nozzle ( Replace nozzle)
makes breathing sound Lack of fuel (in Air) Add fuel
Low grade fuel being used Change to specified fuel
Overheating See item "Indicator of water
Abnormal noise generated temperature gauge is in red
(combustion or mechanical) range on right side of gauge".
Damage inside muffler ( Replace muffler)
Excessive valve clearance ( Adjust valve clearance)
Monitor displays error code
Alarm buzzer sounds
Engine horsepower lowered Please contact your Komatsu distributor
suddenly
(Engine is running in duration
mode)

3 - 163
.

TROUBLESHOOTING OPERATION

WHEN MODE SELECTION SYSTEM FLASHES

If the caution lamp flashes, or it becomes impossible to control the engine speed with the fuel control dial or
decelerator pedal, stop operation immediately, check the monitor panel display, then contact your Komatsu
distributor for repairs.
In addition to the above problems, if any of the problems in the table below occur, there is probably an abnormality
in the work equipment lever switch, transmission speed range sensor, or other part, so please contact your Komatsu
distributor for repairs.

Mode Operation Abnormality

Engine speed varies, difficult to carry out operation
Economy Dozing
No sense of control, engine stays at full or partial
Ripper RAISE speed is slow
Slow reverse Reverse
Slow reverse speed is slow
Lock-up does not work
Lock-up All operations
Gearshifting shock becomes excessive
Traveling under Engine speed becomes partial when traveling under own
-
own power power

3 - 164
.

4-1
.

GUIDES TO MAINTENANCE MAINTENANCE

GUIDES TO MAINTENANCE
Do not perform any inspection and maintenance operation that is not found in this manual.
Stop the machine on flat hard ground when performing inspections and maintenance.

CHECK SERVICE METER:

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

KOMATSU GENUINE REPLACEMENT PARTS:

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

KOMATSU GENUINE OILS:

For lubrication of the machine, use the 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.

CLEAN OIL AND GREASE:

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

CHECK FOREIGN MATERIAL IN DRAINED OIL:

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

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

WELDING INSTRUCTIONS:
Cut off power. Wait for approx. one minute after turning off the engine starting switch key, and then disconnect
the negative (-) terminal of the battery.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3.3 ft) of the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happens to come between the part being welded and grounding point, change the grounding
point to avoid such parts.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.

OBJECTS IN YOUR POCKETS:

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

4-2
.

MAINTENANCE GUIDES TO MAINTENANCE

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

AVOID MIXING OILS:

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

LOCKING INSPECTION COVERS:

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

BLEEDING AIR:
When hydraulic equipment has been repaired or replaced, or the hydraulic piping has been removed and installed
again, the air must be bled from the circuit. For details, see "BLEEDING AIR IN HYDRAULIC SYSTEM (PAGE
4-48)".

PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES:

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

CHECKS AFTER INSPECTION AND MAINTENANCE:

If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may
lead to serious injury or property damage. Always do the following:
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 when engine is running
For the checks when the engine is running, see "TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS
RUNNING (PAGE 2-30)" in the SAFETY section, and take care of safety sufficiently.
Check that the inspected and maintained parts work normally.
Raise the engine speed and check for fuel leakage and oil leakage.

4-3
.

GUIDES TO MAINTENANCE MAINTENANCE

PRECAUTIONS WHEN 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.

4-4
.

MAINTENANCE OUTLINES OF SERVICE

OUTLINES OF SERVICE
Always use 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 problem if the
small amount of oil remaining in the piping mixes with the new oil.)
Unless otherwise specified, the type of oil and coolant used when the machine is shipped from the factory is as
shown in the table below.

Item Type
Engine oil pan Engine oil EO15W40DH (Komatsu genuine parts)
Damper case
Power train oil pan Powertrain oil TO30 (Komatsu genuine parts)
Final drive case
Hydraulic oil system Powertrain oil TO10 (Komatsu genuine parts)
Radiator Supercoolant AF-NAC (density: 30% or above) (Komatsu genuine parts)

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in the
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 problems with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
When the machine is shipped from the factory,T010 (power train oil) is used for the hydraulic system.
When using H046-HM hydraulic oil, drain all the oil and fill with the specified amount of oil.
Always use oil recommended by Komatsu. If any other oil is used, it will cause clogging of the filter.
There is no problem if the new oil is mixed with the small amount of oil remaining in the piping and cylinders.

4-5
.

OUTLINES OF SERVICE MAINTENANCE

FUEL
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C (5
°F)). It is necessary to use the fuel that is suitable for the temperature.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from
the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

NOTICE
Always use diesel oil for the fuel.
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. This device requires high precision parts and lubrication, so if low
viscosity fuel with low lubricating ability is used, the durability may drop markedly.

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 antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine supercoolant
(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.
The Supercoolant is already diluted with distilled water, so it is not flammable.
With the Supercoolant (AF-NAC), the density used for the coolant differs according to the ambient temperature.
For details of the coolant density, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-22)".
Even in areas where it is not considered necessary to prevent freezing, always use Supercoolant (AF-NAC) with
a density of over 30% in order to prevent corrosion of the cooling system.
Supercoolant (AF-NAC) is diluted with distilled water that does not contain any ions or water-hardening
substances. Never dilute the Supercoolant with ordinary water.
When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air entering
the coolant.

4-6
.

MAINTENANCE OUTLINES OF SERVICE

GREASE
Grease is used to prevent seizure and noises at the joints.
This construction equipment is used under heavy-duty conditions. Always use the recommended grease and
follow the change intervals and recommended ambient temperatures given in this Operation and Maintenance
Manual.
The nipples not included in the MAINTENANCE section are nipples used when overhauling, so they do not need
grease.
If any part becomes stiff or generates noise after being used for a long time, grease it.
Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause
wear of the rotating parts.

4-7
.

OUTLINES OF SERVICE MAINTENANCE

CARRYING OUT KOWA (Komatsu Oil Wear Analysis)

The oil clinic samples the oil periodically and analyzes it. This is a preventive maintenance service, which provides
early discovery of abnormal parts and wear of the drive parts of the machine. This then makes it possible to ensure
prevention of failures and reduction in downtime.
Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine
the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair
methods.
The oil clinic charges the customer only the actual costs, and provides an immediate report of the results of the
analysis and recommendations for action to take. This low-cost service can save you high costs and inconvenience
in the future, so we strongly recommend you to avail yourself of this service.

KOWA ANALYSIS ITEMS

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

Measurement of quantity of particles

This uses a PQI (Particle Quantifier Index) measurer to
measure the quantity of iron particles of 5µm or more, enabling
early detection of failures.

Others
Measurements are made of items such as the ratio of water in the oil, density of the antifreeze coolant, ratio of
fuel in the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.

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

4-8
.

MAINTENANCE OUTLINES OF SERVICE

STORING OIL AND FUEL

Keep indoors to prevent any water, dirt, or other impurities from getting in.
When keeping drum cans for a long period, put the drum on its side so that the filler port of the drums is at the side
to prevent moisture from being sucked in.
If drums have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.
To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use the
oldest oil or fuel first).

FILTERS
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
When replacing oil filters, check if any metal particles are attached to the old filter. If any metal particles are found,
contact your Komatsu distributor.
Do not open packs of spare filters until just before they are to be used.
Always use Komatsu genuine filters.

OUTLINE OF ELECTRIC SYSTEM

It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This
will cause an electrical short circuit and may lead to malfunction of the machine. Do not wash the inside of the
operator's cab with water. When washing the machine, be careful not to let water get into the electrical
components.
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and
checking battery fluid level.
Never install any electric components other than those specified by Komatsu.
External electro-magnetic interference may cause malfunction of the control system controller, before installing
a radio receiver or other wireless equipment, contact your Komatsu distributor.
When working at the seashore, carefully clean the electric system to prevent corrosion.
When installing electrical equipment, connect it to the special power source connector.
Do not connect the optional power source to the fuse, starting switch, or battery relay.

4-9
.

OUTLINES OF SERVICE MAINTENANCE

HANDLING HYDRAULIC RELATED EQUIPMENT

During operations and after completion of operations, the hydraulic equipment is at a high temperature. During
operations, it is also under high pressure, so when carrying out inspection and maintenance of hydraulic related
equipment, be careful of the following points.
Stop the machine on flat ground, lower the work equipment completely to the ground, and carry out the
operation so that there is no pressure on the cylinder circuits.
Always stop the engine.
Immediately after stopping operations, the hydraulic oil and lubricating oil is at high temperature and high
pressure, so wait for the oil temperature to go down before starting maintenance.
Even after the temperature has gone down, some parts may still be under internal pressure, so when
loosening plugs, bolts, or hose connections, do not stand directly in front of the parts, and loosen slowly to
release the internal pressure before removing.
When carrying out inspection and maintenance of the hydraulic circuit, always release the air in the hydraulic
tank to remove the internal pressure.
Inspection and maintenance include checking the hydraulic system for oil level, replacement of filter elements
and replacement of hydraulic oil.
If high-pressure hoses have been removed, check that there is no damage to the O-rings. If any damage is found,
replace the O-ring.
It is necessary to bleed the air from the circuits when the hydraulic filter element or strainer have been replaced
or washed, or when hydraulic equipment has been repaired or replaced, or when the hydraulic piping has been
removed.

4 - 10
.

MAINTENANCE WEAR PARTS

WEAR PARTS
Replace wear parts such as the filter element or cutting edge at the time of periodic maintenance or before they
reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of the
machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check for the latest part number when ordering parts.

WEAR PARTS LIST

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

Weight
Item Part No. Part Name Q'ty Replacement
(kg)
Engine oil filter 600-211-1340 Cartridge - 2
07063-51100 Element 1
Power train oil filter -
(07000-12130) (O-ring) (1)
Every 500 hours
07063-51100 Element 1
Steering lubrication oil filter -
(07000-12130) (O-ring) (1)
Fuel pre-filter 600-319-3440 Cartridge - 1
Fuel filter 600-319-3520 Cartridge - 1
Hydraulic tank breather 421-60-35170 Element - 1
Every 1000 hours
Fuel tank breather 421-60-35170 Element - 1
service
07063-51054 Element 1
Charge filter -
(07000-02110) (O-ring) (1)
207-60-71181 Element 1 Every 2000 hours
Hydraulic oil filter -
(07000-15195) (O-ring) (2) service
600-185-6100 Element Ass'y - 1
Air cleaner -
600-185-6110 Outer element - 1
17M-71-48210 Cutting edge 128 2
17M-71-49250 Cutting edge (left) 48 1
17M-71-49260 Cutting edge (right) 48 1
(198-71-21710) (Bolt) - (21)
(195-71-61950) (Washer) - (21)
Blade (Sigmadozer) (198-71-49250) (Nut) - (21) -
17M-71-49271 End bit (left) 74 1
17M-71-49281 End bit (right) 74 1
(198-71-21710) (Bolt) - (14)
(195-71-61950) (Washer) - (14)
(198-71-49250) (Nut) - (14)
195-71-11654 Cutting edge 82 1
17M-71-21550 Cutting edge 81 2
(195-71-52280) (Bolt) - (21)
(01643-22460) (Washer) - (21)
(17M-71-21530) (Nut) - (21)
Blade (Sem U-Dozer) -
17M-71-21930 End bit (left) 63 1
17M-71-21940 End bit (right) 63 1
(195-71-52280) (Bolt) - (14)
(01643-22460) (Washer) - (14)
(17M-71-21530) (Nut) - (14)

4 - 11
.

WEAR PARTS MAINTENANCE

Weight
Item Part No. Part Name Q'ty Replacement
(kg)
195-71-11654 Cutting edge 82 2
17M-72-21160 Cutting edge 58 2
(195-71-52280) (Bolt) - (24)
(01643-22460) (Washer) - (24)
(17M-71-21530) (Nut) - (24)
Blade (U-Dozer) -
17M-71-21930 End bit (left) 63 1
17M-71-21940 End bit (right) 63 1
(195-71-52280) (Bolt) - (14)
(01643-22460) (Washer) - (14)
(17M-71-21530) (Nut) - (14)
17M-78-21330 Protector 15 3
Ripper
195-78-21331 Point 17 3 -
(variable multi ripper)
(09244-02508) (Pin) - (9)
17M-78-21330 Protector 15 1
Ripper
195-78-21331 Point 17 1 -
(variable giant ripper)
(09244-02508) (Pin) - (3)

NOTICE
When handling parts that weigh more than 25 kg (55 lb), remember that they are heavy objects, and take the necessary care.

4 - 12
.

MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT

RECOMMENDED FUEL, COOLANT, AND LUBRICANT

Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment
and components.
In order to keep your machine in the best conditioner for long periods 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 excess wear of the engine, power train,
cooling system, and/or other components.
Commercially available lubricant additives may be good for the machine, but they may also cause harm.
Komatsu does not recommend any commercially available lubricant additive.
Use the oil recommended according to the ambient temperature in the chart below.
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity means
the amount of oil needed to refill the system during inspection and maintenance.
When starting the engine in temperatures below 0°C (32°F), be sure to use the recommended multi-grade oil,
even if the ambient temperature may become higher during the course of the day.
If the machine is operated at a temperature below -20°C (-4°F), a separate device is needed, so consult your
Komatsu distributor.
When the fuel sulfur content is less than 0.2%, change the engine oil according to the period inspection table
given in this Operation and Maintenance Manual.
If the fuel sulfur content is more than 0.2%, change the oil according to the following table.

Sulfur content (%) Oil change interval

Less than 0.2 % 500 hours

0.2 to 0.5 % 250 hours
0.5 and up Not recommendable (*)

* If these fuels are used, there is danger that serious trouble may occur because of early deterioration of the engine
oil or early wear of the internal parts of the engine. If the local situation makes it necessary to use these fuels,
always remember the following.
1) Be sure to check Total Basic Number (TBN) of oil frequently by TBN handy checker etc., and change oil
based on the result.
2) Always be aware that oil change interval is extremely shorter than standard.
3) Be sure to carry out periodic engine inspection by distributor's expert since change interval of periodic
replacement parts and overhaul interval are also shorter.

4 - 13
.

RECOMMENDED FUEL, COOLANT, AND LUBRICANT MAINTENANCE

Power train oil pan Final

Engine
(incl. transmission, Damper drive Hydraulic Fuel Cooling
oil
torque converter and case case system tank system
pan
bevel gear casses) (each)

Specified Liter 55 150 1.5 40 270 840 110

amount US gal 14.53 39.63 0.40 10.57 71.33 221.93 29.06

Refil Liter 50 90 1.5 40 130 - -

capacity US gal 13.21 23.78 0.40 10.57 34.35 - -

4 - 14
.

MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT

NOTICE
Always use diesel oil for the fuel.
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. This device requires high precision parts and lubrication, so if low
viscosity fuel with low lubricating ability is used, the durability may drop markedly.

Note 1: HTHS ( High-Temperature High-Shear Viscosity 150°C), specified by ASTM D4741 must be equal to or
higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.

Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.

Note 3: Hyper 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: Supercoolant (AF-NAC)

1) Coolant has the important function of anticorrosion as well as antifreeze.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
2) For details of the Supercoolant AF-NAC density, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-22)".
Supercoolant AF-NAC is supplied already diluted. In this case, add the pre-diluted fluid to keep the tank full.
(Never dilute the Supercoolant with ordinary water.)
3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant
between 30% and 68%.

RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN

KOMATSU GENUINE OIL
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.

4 - 15
.

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS MAINTENANCE

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

TORQUE LIST
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and
this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was
replaced.

Thread Width Tightening torque

diameter across
Target value Service limit
of bolt flats
(a)(mm) (b)(mm) Nm kgm lbft Nm kgm lbft

6 10 13.2 1.35 9.8 11.8-14.7 1.2-1.5 8.7-10.8

8 13 31 3.2 23.1 27-34 2.8-3.5 20.3-25.3
10 17 66 6.7 48.5 59-74 6.0-7.5 43.4-54.2
12 19 113 11.5 83.2 98-123 10.0-12.5 72.3-90.4
14 22 172 17.5 126.6 153-190 15.5-19.5 112.1-141

16 24 260 26.5 191.7 235-285 23.5-29.5 170.0-213.4

18 27 360 37 267.6 320-400 33.0-41.0 238.7-296.6
20 30 510 52.3 378.3 455-565 46.5-58.0 336.3-419.5
22 32 688 70.3 508.5 610-765 62.5-78.0 452.1-564.2
24 36 883 90 651 785-980 80.0-100.0 578.6-723.3

27 41 1295 132.5 958.4 1150-1440 118.0-147.0 853.5-1063.3

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

Apply the following table for Hydraulic Hose.

Width Tightening torque
Nominal-
across
No. of Target valve Parmissible range
flats (b)
threads (a)
mm Nm kgm lbft Nm kgm lbft

9/16 -18UNF 19 44 4.5 32.5 34 - 54 3.5 - 5.5 25.3 - 39.8

11/16 -16UN 22 74 7.5 54.2 54 - 93 5.5 - 9.5 39.8 - 68.7

13/16 -16UN 27 103 10.5 75.9 84 - 132 8.5 - 13.5 61.5 -97.6
1 -14UNS 32 157 16.0 115.7 128 - 186 13.0 - 19.0 94.0 - 137.4

1·3/16 -12UN 36 216 22.0 159.1 177 - 245 18.0 - 25.0 130.2 - 180.8

4 - 16
.

MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

For using the machine safely for an extended period of time, you are required to periodically replace the safety
(critical and fire prevention) related parts listed in the table of important parts on the following page.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is required
to replace them with new ones regardless of their condition after a certain period of usage. This is important to
ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the periodic
replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose
clamps and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
Have your Komatsu distributor replace the critical parts.

SAFETY CRITICAL PARTS

Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before
they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of the
machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check for the latest part number when ordering parts.

NO. Safety critical parts for periodic replacement Q'ty Replacement interval
1 Fuel hose (nozzle - fuel return hose) 1
2 Fuel hose (scavenging pump - fuel return hose) 1
3 Fuel hose (fuel tank - fuel strainer) 1
4 Fuel hose (fuel strainer - scavenging pump) 1
5 Fuel hose (hand priming pump - supply pump) 1
6 Hose (torque converter oil cooler - power train assembly) 2
7 Hose (power train pump - transmission filter / steering filter) 2
8 Hose (transmission filter - power train assembly) 1
9 Hose (steering filter - power train assembly) 1
10 Inspection hose assembly for power train pressure 1 Every 2 years
or 4000 hours,
11 Hose (HSS charge pump - HSS charge filter) 1 whichever comes sooner
12 Hose (HSS charge filter - HSS pump) 1
13 Hose (HSS charge filter - HSS motor) 1
14 Hose (HSS pump - central drain block) 1
15 Hose (HSS motor - central drain block) 1
16 Hose (drain relay block - hydraulic tank) 2
17 Hose (HSS pump - HSS motor) 2
18 Hose (self-reducing pressure valve - HSS pump) 1
19 Hose (HSS pump - pivot turn valve) 1
20 Hose (pivot turn valve - HSS motor) 1

4 - 17
.

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS MAINTENANCE

NO. Safety critical parts for periodic replacement Q'ty Replacement interval
21 Hose (pivot turn valve - drain relay block) 1
22 Hose (HSS motor - oil cooler bypass valve) 1
23 Hose (oil cooler bypass valve - hydraulic oil cooler) 2
24 Hose (fan pump - self-reducing pressure valve) 1
25 Hose (self-reducing pressure valve - relay tube) 1
26 Hose (relay tube - fan motor) 2
27 Hose (fan motor - hydraulic tank) 4
28 Hose (self-reducing pressure valve - PPC lock valve) 2
29 Hose (PPC lock valve - blade PPC valve) 1
30 Hose (PPC lock valve - ripper PPC valve) 1
31 Hose (blade PPC valve - main control valve) 4
32 Hose (ripper PPC valve - main control valve) 4
33 Hose (blade PPC valve - hydraulic tank) 1 Every 2 years
or 4000 hours,
34 Hose (ripper PPC valve - hydraulic tank) 1 whichever comes sooner
35 Hose (hydraulic pump - main control valve) 3
36 Hose (main control valve - ripper relay block) 4
37 Hose (main control valve - hydraulic tank) 1
38 Hose (ripper relay block - ripper cylinder) 8
39 Hose (main control valve - blade tilt relay tube) 4
40 Hose (main control valve - blade relay tube) 2
41 Hose (blade relay tube - blade divider block) 2
42 Hose (radiator guard top - lift cylinder) 2
43 Accumulator (for control circuit) 1
44 Hose (air cleaner - turbocharger) 1
45 Hose (turbocharger - aftercooler) 2
46 Hose (aftercooler - engine) 1
47 High-pressure tube clamp 15
Every 8000 hours
48 Fuel spray prevention cap 17
49 Seat belt 1 Every 3 years

4 - 18
.

MAINTENANCE MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART

INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
REPLACE POWER TRAIN OIL FILTER ELEMENT, STEERING LUBRICATING OIL FILTER
ELEMENT 4- 60
CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER,
SCAVENGING PUMP STRAINER) 4- 67
REPLACE CHARGE FILTER ELEMENT 4- 71
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT,
CLEAN HYDRAULIC TANK STRAINER 4- 72
CHANGE OIL IN FINAL DRIVE CASE 4- 74

WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM 4- 22
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4- 25
CHECK AND ADJUST TRACK TENSION 4- 30
CHECK AND TIGHTEN TRACK SHOE BOLTS 4- 33
ADJUST IDLER CLEARANCE 4- 34
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES 4- 35
CLEAN AND CHECK RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS 4- 37
CLEAN FUEL TANK STRAINER 4- 40
DRAIN WATER AND SEDIMENT IN FUEL TANK 4- 40
CLEAN STEERING CASE BREATHER 4- 41
CLEAN FUEL TANK BREATHER 4- 41
CLEAN HYDRAULIC TANK BREATHER 4- 41
CHECK UNDERCARRIAGE OIL 4- 42
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) 4- 43
REPLACE AIR CONDITIONER BELT 4- 43
CHECK AND ADJUST AIR CONDITIONER 4- 44
LUBRICATE DOOR HINGE 4- 45
CHECK DOOR LATCH 4- 45
CHECK DOOR LOCK STRIKER 4- 45
REPLACE DOOR DAMPER 4- 46
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID 4- 46
REPLACE WIPER BLADE 4- 47
BLEEDING AIR IN HYDRAULIC SYSTEM 4- 48
LUBRICATING 4- 49

CHECK BEFORE STARTING

EVERY 250 HOURS SERVICE

LUBRICATING 4- 51
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST 4- 53
CHECK LEVEL OF BATTERY ELECTROLYTE 4- 54
CHECK BRAKE PERFORMANCE 4- 56
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL 4- 57

4 - 19
.

MAINTENANCE SCHEDULE CHART MAINTENANCE

EVERY 500 HOURS SERVICE

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 58
REPLACE POWER TRAIN OIL FILTER ELEMENT, STEERING LUBRICATING OIL FILTER
ELEMENT 4- 60
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL 4- 61
REPLACE FUEL PRE-FILTER CARTRIDGE 4- 62

EVERY 1000 HOURS SERVICE

REPLACE FUEL MAIN FILTER CARTRIDGE 4- 64
REPLACE FUEL TANK BREATHER ELEMENT 4- 66
REPLACE HYDRAULIC TANK BREATHER ELEMENT 4- 66
CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER,
SCAVENGING PUMP STRAINER) 4- 67
CHECK, CLEAN FUEL STRAINER 4- 69
CHECK FOR LOOSE ROPS MOUNT BOLTS 4- 69
CHECK HOSE CLAMPS BETWEEN AIR CLEANER AND TURBOCHARGER,
TURBOCHARGER AND AFTERCOOLER, AFTERCOOLER AND ENGINE 4- 70
REPLACE CHARGE FILTER ELEMENT 4- 71

EVERY 2000 HOURS SERVICE

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN
HYDRAULIC TANK STRAINER 4- 72
CHANGE OIL IN FINAL DRIVE CASE 4- 74
CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER 4- 75
CHECK PIVOT BEARING OIL LEVEL, ADD OIL 4- 77
CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL 4- 77
CHECK ALTERNATOR 4- 78
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 78
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL
CIRCUIT) 4- 78

EVERY 4000 HOURS SERVICE

REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT ) 4- 82
CHECK WATER PUMP 4- 82
CHECK STARTING MOTOR 4- 82
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER 4- 83
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 4- 84
CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER) 4- 85

EVERY 8000 HOURS SERVICE

REPLACE HIGH-PRESSURE PIPING CLAMP 4- 86
REPLACE FUEL SPLAY PREVENTION CAP 4- 86

4 - 20
.

MAINTENANCE SERVICE PROCEDURE

SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
Perform the following maintenance only after the first 250 hours.
Replase power train oil filter element, steering lubricating oil filter element
Change oil in power train case, wash strainers (power train pump strainer, scavenging pump strainer)
Replace charge filter element
Change oil in hydraulic tank, replace hydraulic oil filter element, clean hydraulic tank strainer
Change oil in final drive case
For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS, 1000 HOURS and
2000 HOURS SERVICE.

4 - 21
.

SERVICE PROCEDURE MAINTENANCE

WHEN REQUIRED

CLEAN INSIDE OF COOLING SYSTEM

WARNING
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the temperature to go down, then
turn the cap slowly to release the pressure before removing it.
Cleaning is carried out with the engine running. When standing up or leaving the operator's seat, set the work equipment lock
lever and the parking brake lever to the LOCK position.
For details of starting the engine, see "CHECK BEFORE STARTING ENGINE, ADJUST (PAGE 3-73)" and "STARTING ENGINE
(PAGE 3-95)" in the OPERATION section.
Never enter front the machine when the engine is running.
There is danger of touching the fan.

Stop the machine on level ground when cleaning or changing the coolant.

Clean the inside of the cooling system, change the coolant according to the table below.

Interval for cleaning inside of cooling system

Antifreeze coolant
and changing antifreeze coolant

Komatsu supercoolant Every two years or every 4000 hours

(AF-NAC) whichever comes first

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 antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
As a basic rule, we do not recommend the use of any coolant other than Komatsu genuine supercoolant (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.
To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
Supercoolant (AF-NAC) is already diluted with distilled water. When using coolant, investigate the lowest
temperatures in the past and decide the density for the coolant from the coolant density table below.
When actually deciding the density for the coolant, set it for a temperature 10°C (18°F) lbelow the actual
temperature.
The coolant density varies according to the ambient temperature, but it must always be a minimum of 30%.

Coolant density table

°C Above -10 -15 -20 -25 -30 -35 -40 -45 -50
Minimum Temp
°F Above 14 5 -4 -13 -22 -31 -40 -49 -58
Concentration (%) 30 36 41 46 50 54 58 61 64
Prepare a hose to use when filling with coolant.

4 - 22
.

MAINTENANCE SERVICE PROCEDURE

WARNING
Antifreeze is toxic. When open the drain valve, be careful not to get water containing antifreeze on you. If it gets in your eyes,
flush your eyes with large amount of fresh water and see a doctor at once.
When changing the coolant or draining the coolant from the radiator before carrying out repairs, ask a specialist company to
handle any coolant containing antifreeze, or contact your Komatsu distributor. Antifreeze is toxic, so never pour it into
drainage water ditches or drain it onto the ground surface.

The coolant is already diluted with distilled water. (For details of the distilled water, see "COOLANT AND WATER
FOR DILUTION (PAGE 4-6)". Check the density with a coolant tester.

1. Turn radiator cap (1) slowly and remove it.

2. Prepare for a container to receive drained super coolant-

mixed cooling water, pull out radiator hose (2) tucked away in
the lower portion of the machine's front right side, and then
open drain valve (3) to drain the water.
3. Open drain valve (4) fitted to the water pump piping on the
engine's right side to drain water.
4. After draining the coolant, close drain valves (3) and (4), and fill
with city water.

5. When the radiator is filled with water, start the engine, run at
low idling, raise the water temperature to at least 90 °C, then
run the engine for approx. 10 minutes.
6. Stop the engine and open drain valves (3), (4) to drain the
water.
7. After draining the water, clean the cooling system with cleaning
agent.
For the cleaning method, see the instructions for the cleaning
agent.

8. Close drain valve (3)(4) and add Supercoolant to near the mouth of the water filler.
For details of the Supercoolant density, see the COOLANT DENSITY TABLE.
9. To bleed the air mixed in the coolant, run the engine at low idling for 5 minutes, then run for a further 5 minutes
at high idling.
(When doing this, leave the water filler cap off.)

4 - 23
.

SERVICE PROCEDURE MAINTENANCE

10. Open reserve tank cap (5), add coolant to the specified level
in reference to "CHECK COOLANT LEVEL, ADD COOLANT
(PAGE 3-76)", and then close cap (5).

11. Stop the engine, wait for approx. 3 minutes, add Supercoolant
up to the bottom of the filler port, then tighten the radiator cap
(1).

4 - 24
.

MAINTENANCE SERVICE PROCEDURE

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

WARNING
Always wear protective glasses, dust mask, or other protective equipment.
When removing the air cleaner element from the air cleaner body, it is dangerous to pull it out by force.
When working at high places or where the foothold is poor, be careful not to fall because of the reaction when pulling out the
outer element.

CHECKING
If the internal yellow piston overlaps the red zone (A) on the outside
diameter of dust indicator (1), clean the air cleaner element.
After cleaning, press the reset button to reset the piston.

NOTICE
Do not clean the element until the yellow piston in dust indicator (1)
overlaps the red zone (A) on the outer diameter.
If the element is cleaned frequently before the yellow piston in dust
indicator (1) overlaps the red zone (A) on the outer diameter, the air cleaner
will not be able to provide its expected performance and the cleaning
efficiency will become poor.
In addition, dirt stuck to the element will drop inside the inner element more
frequently during the cleaning operation.

4 - 25
.

SERVICE PROCEDURE MAINTENANCE

CLEANING OUTER ELEMENT

NOTICE
Before and after cleaning the element, do not leave or keep it in direct
sunlight.

1. Remove 6 holders (2), then remove cover (3) and take out
outer element (4).

NOTICE
Never remove the inner element (5). It will allow dirt to enter and cause
failure of the engine.
Do not use a screwdriver or other tool.

2. Hold the outer element (4), move it carefully up and down and
to the left and right, and rotate the element to the left and right
while pulling it out.

3. After removing the outer element, cover the air connector

inside the air cleaner body with a clean cloth or tape to prevent
dirt or dust from entering.
4. Use a brush or cloth to remove all the dirt stuck to cover (3) and
the inside of air cleaner body (6).

5. Direct dry compressed air (Max. 0.69 MPa (7 kg/cm2, 99.4

PSI)) from the inside of the outer element along its folds. Then
direct the compressed air from the outside along the folds, and
again from the inside.
1) Check that the inner element is not loose. If it is loose,
insert it securely.
2) If the yellow piston overlaps the red zone (A) on the outer
diameter immediately after the outer element is cleaned,
replace both the inner and outer elements.

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 an element whose folds or gasket or seal are damaged.

4 - 26
.

MAINTENANCE SERVICE PROCEDURE

6. 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.

NOTICE
The inner element must not be cleaned and used again. When replacing
the outer element, replace the inner element at the same time.
If the inner element is not installed properly and the outer element and
cover are installed, there is danger that the outer element will be
damaged.
The seal portion on imitation parts lacks precision, and allows the entry
of dust, which leads to damage of the engine. Do not use such imitation
parts.

7. Remove the cloth or tape cover installed in Step 3.

8. Check that there is no dirt or oil stuck to the seal portion of the
new element or cleaned element. Wipe off any dirt or oil.
9. Push the outer element in straight with your hand when
installing it to the air cleaner body.
If the outer element is held and rocked lightly up and down and
to the left and right while pushing it in, the outer element can be
inserted easily.

NOTICE
When inserting the element, if the rubber at the tip is swollen or the outer
element is not pushed in straight, and cover (3) is assembled by force to
hook (2), there is danger that the hook and air cleaner body may be
damaged, so be careful when assembling.

10. Install cover (3) as follows.

1) Align cover (3) with the element.
2) Hook the tip of hook (2) to the protruding part of the air
cleaner body and lock it in position.
3) When locking hooks (2) in position, apply the hooks in turn
on opposite sides (top, bottom, left, right) in the same way
as when tightening bolts.
4) When cover (3) is installed, check that the clearance
between the air cleaner body and cover (3) is not too large.
If it is too large, install again.

4 - 27
.

SERVICE PROCEDURE MAINTENANCE

REPLACING ELEMENT
1. Open the left engine side cover.
2. Remove 6 holders (2), then remove cover(3).

3. Hold the outer element (4), move it carefully up and down and
to the left and right, and rotate the element to the left and right
while pulling it out.

4. Use a brush or cloth to remove all the dirt stuck to cover (3) and
the inside of air cleaner body (6).

NOTICE
The inner element must not be cleaned and used again. When replacing the outer element, replace the inner element at the
same time.
If the inner element is not installed properly and the outer element and cover are installed, there is danger that the outer element
will be damaged.
The seal portion on imitation parts lacks precision, and allows the entry of dust, which leads to damage of the engine. Do not
use such imitation parts.

5. Remove inner element (5), then quickly install the new inner
element.
Push the inner element in properly and check that it is fitted
securely.
6. Push new outer element (4) straight into the air cleaner body
with your hand.
If you hold the element and move it carefully up and down and
to the left and right, it is easier to insert the element.
7. Replace O-ring (7) for cover (3) with new one.

4 - 28
.

MAINTENANCE SERVICE PROCEDURE

NOTICE
When inserting the element, if the rubber at the tip is swollen or the outer
element is not pushed in straight, and cover (3) is assembled by force to
hook (2), there is danger that the hook and air cleaner body may be
damaged, so be careful when assembling.

8. Install cover (3) as follows.

1) Align cover (3) with the element.
2) Hook the tip of hook (2) to the protruding part of the air
cleaner body and lock it in position.
3) When locking hooks (2) in position, apply the hooks in turn
on opposite sides (top, bottom, left, right) in the same way
as when tightening bolts.
4) When cover (3) is installed, check that the clearance
between the air cleaner body and cover (3) is not too large.
If it is too large, install again.
9. After replacing the element, press the dust indicator button to
reset it.
The yellow piston will return to its original position.

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SERVICE PROCEDURE MAINTENANCE

CHECK AND ADJUST TRACK TENSION

The wear of pins and bushings on the undercarriage will vary with the working conditions and types of soil. It is thus
necessary to continually inspect the track tension so as to maintain the standard tension.
Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track
becomes clogged with mud, measure with the track clogged with mud).

INSPECTION
Stop the machine on level ground (stop with the transmission in
FORWARD without applying the brake). Then place a straight bar
on the track shoes between the carrier roller and the idler as shown
in the figure, and measure the clearance between the bar and the
grouser at the midpoint. If the clearance (A) is 20 to 30 mm (0.79
to 1.18 in), the tension is standard.
If the track tension is not at the standard value, adjust it in the
following manner.

ADJUSTMENT

WARNING
Grease inside the adjusting mechanism is under high pressure.
Grease coming from plug (4) under pressure can penetrate the body
causing injury or death. For this reason, do not loosen plug (4) more than
one turn. Do not loosen any part other than plug (4). Furthermore, do not
bring your face in front of the grease fitting.
If track tension is not relieved by this procedure, contact your Komatsu
distributor for repairs.

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MAINTENANCE SERVICE PROCEDURE

WHEN INCREASING TENSION

1. First remove the bolt (1) and then remove the cover (2).

NOTICE
When removing cover (2), be careful not to let any dirt get inside.
There is a safety label stuck to the back of cover (2). Be careful not to damage the safety label.

2. Pump in grease through the grease fitting (3) with a grease pump.
3. To check that the correct tension has been achieved, move the machine backwards and forwards.
4. Check the track tension again, and if the tension is not correct, adjust it again.
5. Continue to pump in grease until S becomes 475 mm (18.7 in).
If the tension is still loose, the pin and bushing are excessively
worn, so they must be either turned or replaced. Please
contact your Komatsu distributor.

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.

SERVICE PROCEDURE MAINTENANCE

WHEN LOOSENING TENSION

WARNING
It is extremely dangerous to release the grease by any method except the procedure given below.
If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs.

1. Remove both bolts (1), then remove cover (2).

NOTICE
When removing cover (2), be careful not to let any dirt get inside.
There is a safety label stuck to the back of cover (2). Be careful not to
damage the safety label.

2. Loosen plug (4) gradually to release the grease.

3. Turn plug (4) a maximum of one turn.
4. If the grease does not come out smoothly, move the machine
backwards and forwards a short distance.
5. Tighten plug (4).
6. To check that the correct tension has been achieved, move the
machine backwards and forwards.
7. Check the track tension again, and if the tension is not correct,
adjust it again.

WHEN REMOVING TRACK

WARNING
Depending on the situation, the operation to remove the track may be extremely dangerous.
Before removing the track, if the procedure "WHEN LOOSENING TENSION (PAGE 4-32)" does not loosen the track tension, contact
your Komatsu distributor for repairs.

4 - 32
.

MAINTENANCE SERVICE PROCEDURE

CHECK AND TIGHTEN TRACK SHOE BOLTS

If the machine is used with track shoe bolts being loose, they will break, so tighten any loose bolts immediately.

METHOD OF TIGHTENING SHOE BOLT

1. First tighten to a tightening torque of 490 ± 49 Nm (50 ± 5 kgm, 361.7 ± 36.2 lbft) then check that the nut and
shoe are in close contact with the link contact surface.
2. After checking, tighten a further 180° ± 10°.

METHOD OF TIGHTENING MASTER LINK CONNECTING BOLT

1. First tighten to a tightening torque of 490 ± 49 Nm (50 ± 5 kgm, 361.7 ± 36.2 lbft) then check that the link contact
surfaces are in close contact.
2. After checking, tighten a further 180° ± 10°.

ORDER FOR TIGHTENING

Tighten the bolts in the order shown in the diagram on the right.

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.

SERVICE PROCEDURE MAINTENANCE

ADJUST IDLER CLEARANCE

The idler moves forward and backward under external pressure
when this happens, side guide (1) and guide plate (2) become
worn.
As they become worn, there is side play in the idler, or the idler
turns at an angle, causing the track to come off or resulting in
uneven wear, so adjust as follows.

ADJUSTMENT
1. Drive the machine for 8 to 12 m (24.4 to 36.6 ft) on flat ground,
then measure clearance A (4 places: left, right, inside outside)
between the track frame and side guide (1).
2. If clearance A is more than 3 mm (0.1 in), remove bolt (3), then
take out shim (4), and adjust to that the clearance on one side
is less than 0.5 mm (0.02 in).

REMARK
There are two types of shim
(thickness: 0.5 mm (0.02 in) and 1.0 mm (0.04 in)).

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.

MAINTENANCE SERVICE PROCEDURE

REVERSE AND REPLACE THE END BITS AND CUTTING EDGES

WARNING
It is dangerous if the work equipment moves by mistake when the cutting edges and end bits are being reversed or replaced.
Set the work equipment in a stable condition, then stop the engine and lock the blade control lever securely with the work
equipment lock lever.

Reverse or replace the cutting edges and end bits before the wear reaches the mounting surface.
1. Raise the blade to a proper height, position a block under the frame to prevent the blade from falling.
2. Operate the work equipment lock lever to the LOCK position.
3. Loosen nut (1) and remove bolt (2). Then remove the cutting
edge and the end bit and clean the mounting surface.

4. Reverse or replace the cutting edge and the end bit when worn
out.
If bolt (1) and nut (2) are damaged, replace them with new ones
at the same time.

5. Install the edge to the blade, then tighten partially. Drop the
blade three to five times on to the ground or rock to remove any
play in bolt (2), then tighten it to the correct tightening torque.
When installing end bit (3), put top surface (4) of the end bit in
close contact with stopper (5), then tighten with the bolts.
Semi U-dozer, U-dozer
Tightening torque: 1499 ± 157 Nm (153 ± 16 kgm, 1106.6
± 115.7 lbft)
Sigmadozer
Tightening torque: 2226 ± 275 Nm (227 ± 28 kgm, 1641.5
± 202.5 lbft)
6. After several hours of running, retourque the nuts.
Reverse or replace the cutting edges and end bits before the wear reaches the mounting surface.

REMARK
The tip (a) of mount plate (b) may wear away when the end bits
and cutting edges are replaced or reversed. This wearing
shape does not affect the blade life.
If both sides of the cutting edge are worn, replace with a new
part.
If the wear reaches the mounting surface, repair the mounting
surface before replacing the part.

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.

SERVICE PROCEDURE MAINTENANCE

REMARK
The tightening operation is easier if the power wrench that has been supplied is used.

When the nut is rusted and is removed by gas cutting, cut on both
side (6) of the nut as shown in the diagram.
Be careful not to damage seat surface (7).
If it is damaged, repair it. Be careful not to get spatter on the
mounting surface.

METHOD OF USING POWER WRENCH

The power wrench set is equipped with a special socket.
This socket is designed to grip the nuts and prevent the wrench set
from pulling out. This means that tightening can be performed by
one worker.
This socket has a double construction, and is designed so that the
outside can rotate 30°
It is used as follows.
(1) Cutting edges or end bit
(2) Ratchet handle or torque wrench
(3) Rotating socket
(4) Reaction arm
1. Align the hexagons of the inside socket (6) and outside socket
(5), the insert the nut that is to be tightened or loosened.
2. After inserting the nut, turn the outside socket (5) 30· clockwi
se (7).
When this is done, the outside socket will catch the notch in the
nut seat surface, and the wrench will not come off.
3. Put the reaction arm (4) in contact with the blade rib, and
tighten or loosen.
4. Turn the outside socket (5) counterclockwise, and remove the
wrench.

4 - 36
.

MAINTENANCE SERVICE PROCEDURE

CLEAN AND CHECK RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS
Carry out this procedure if there is any mud or dirt stuck to the radiator or oil cooler.

REMARK
Check the hydraulic cooler hoses. If any hose is cracked or hardened by age, replace with a new hose. Also check
and tighten all loose hose clamps.

CLEANING BY ROTATING COOLING FAN IN REVERSE DIRECTION

WARNING
When cleaning the cooling fan by turning it in the reverse direction, make sure that the parking brake lever is in the LOCK position.

NOTICE
When rotating the cooling fan in the reverse direction, be extremely careful of flying dust.
Open up the right and left engine side covers and check that no dust and dirt are accumulated inside the engine room.
When the fan reversal lamp is lighted and the fan is turning in the reverse direction, the machine does not move even if the steering
- forward and reverse - gearshift lever is operated to any of the forward, reverse and steering positions. This function is designed
to protect the radiator.
When stopping the engine when the cooling fan is rotating in the reverse direction, first run the engine at low idling, then stop it.

The dust and dirt stuck to the radiator and cooler can be blown out by rotating the cooling fan in the reverse direction.
1. Turn starting switch (1) to the "OFF" position and stop the
engine.
2. Turn starting switch (1) to the "ON" position.

3. Turn fan rotation selector switch (2) to the cleaning (CLN)

position.
Fan reversal lamp (3) lights up.

4 - 37
.

SERVICE PROCEDURE MAINTENANCE

REMARK
Even if the fan rotation selector switch is turned while the engine is
running, the fan does not change its rotation direction.
Then fan rotation selection impossibility lamp (4) flashes, telling
you that the fan rotation cannot be switched.

4. Start up the engine by turning engine starting switch key (1).

The cooling fan begins to turn in the reverse direction.
5. Run the engine at high idle.

Select the time for running the engine at high idle as follows according to the condition of clogging.
Normal clogging: 1 to 2 minutes
Excessive clogging: 2 to 3 minutes

6. After completing the cleaning, run the engine at low idle for approx. 10 seconds.
7. Turn starting switch (1) to the "OFF" position and stop the engine.

REMARK
When the cooling fan is turning for cleaning, power cannot be switched off immediately, even if the engine starting
switch key is turned to the OFF position in order to protect the hydraulic circuit.

8. Turn starting switch (1) to the "ON" position.

9. Check that fan reversal lamp (3) is unlighted and start up the
engine. The cooling fan begins to turn in the normal direction.

REMARK
If dirt is caught in the radiator fins, blow with compressed air to
clean.

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.

MAINTENANCE SERVICE PROCEDURE

CLEANING WITH COMPRESSED AIR

WARNING
Directing compressed air, pressurized water, or steam directly at your body, or using these and causing dust to fly may cause
personal injury. Always wear protective glasses, anti-dust mask, and other protective equipment.
When carrying out 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.

NOTICE
When using compressed air for cleaning, blow it keeping some distance to avoid damaging the fins. Damage on the fins can cause
water leakage and overheating. In a dusty job site, check the fins every day, regardless of the maintenance interval.

CLEAN RADIATOR FINS

1. Remove bolts (1) at the center and four corners of the radiator
grill, then open radiator grill (2).
2. Clean the radiator fins clogged with mud, dust and leaves with
compressed air. Steam or water may be used instead of
compressed air.

REMARK
Check the hydraulic cooler hoses. If any hose is cracked or hardened by age, replace with a new hose. Also check
and tighten all loose hose clamps.

CLEAN OIL COOLER FINS

1. Open up the engine side cover on the left side of the machine.
2. Use compressed air to remove the mud, dirt, and leaves
clogging the hydraulic cooler fins. Steam or water may be used
instead of compressed air.

REMARK
Check the hydraulic cooler hoses. If any hose is cracked or hardened by age, replace with a new hose. Also check
and tighten all loose hose clamps.

4 - 39
.

SERVICE PROCEDURE MAINTENANCE

CLEAN AFTERCOOLER FINS

1. Open the engine side cover on the right side of the machine.
2. Blow off dirt, dust and dry leaf shreds that clog the after-cooler
fins, with compressed air. Steam or water may well be used for
this purpose instead of compressed air.

REMARK
Check the hydraulic cooler hoses. If any hose is cracked or hardened by age, replace with a new hose. Also check
and tighten all loose hose clamps.

CLEAN FUEL TANK STRAINER

Clean the strainer if there is any dirt collected in it.
Remove the filler cap (1) of the fuel tank and take out strainer.
If the strainer is dirty, clean it with diesel fuel.

DRAIN WATER AND SEDIMENT IN FUEL TANK

Carry out this procedure after the machine has been at rest for a
long time and after a long spell of rainy days.
Loosen valve (1) at the bottom of the fuel tank, and drain the water
and sediment collected at the bottom of the tank together with the
fuel.

4 - 40
.

MAINTENANCE SERVICE PROCEDURE

CLEAN STEERING CLUTCH CASE BREATHER

1. Open the rear cover.
2. Remove bolts (1), then remove cover (2).
3. Remove breather (3) on the side of the hydraulic tank, remove
any dirt stuck to the breather, then wash with clean diesel oil or
flushing oil.

CLEAN FUEL TANK BREATHER

Remove breather (1) on the side of the fuel tank, remove any dirt
stuck to the breather, then wash with clean diesel oil or flushing oil.

CLEAN HYDRAULIC TANK BREATHER

Remove breather (1) on the side of the hydraulic tank, remove any
dirt stuck to the breather, then wash with clean diesel oil or flushing
oil.

4 - 41
.

SERVICE PROCEDURE MAINTENANCE

CHECK UNDERCARRIAGE OIL

Stop the machine on level ground, and check for any reduction in
the oil at the idler (portion P), track roller (portion Q), and carrier
roller (portion R).

1. Loosen seal bolt (1) slowly and check if oil oozes out from the
thread. If oil oozes out, the oil level has not gone down, so
tighten the bolt.
2. If no oil comes out even when seal bolt is removed, the oil level
is low. Contact your Komatsu distributor for repairs.

REMARK
Bogie shaft seal bolt (1) is located on both the inside and outside.

4 - 42
.

MAINTENANCE SERVICE PROCEDURE

CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)

Clean the air conditioner air filter if it becomes clogged or if there is
dirt or oil stuck to it.
1. Open inspection cover (1) and remove fresh air filter (2).

2. Open inspection cover (3) under the front panel and pull up
recirculation air filter (4) to remove it.
3. Clean filters (2) and (4) with compressed air. If there is oil stuck
to the filter, or it is extremely dirty, wash it in a neutral agent.
After washing it, dry it completely before installing it again.

REMARK
If the filters cannot be cleaned with air or in water, replace them with new ones.

REPLACE AIR CONDITIONER BELT

1. Loosen 4 bolts (1) and jack bolt (2), then move compressor (3)
to the side.
2. Replace the V-belt.
When adjusting the V-belt, do not push the compressor
directly with the bar. Use jack bolt (2).
3. Tighten jack bolt (2) and bolts (1), and apply tension to the
V-belt. The standard deflection for the belt is approx. 10 mm
(0.4 in) when pressed with a finger force of approx. 58.8N (6
kg) at a point midway between the air conditioner compressor
pulley and fan pulley.

4 - 43
.

SERVICE PROCEDURE MAINTENANCE

CHECK AND ADJUST AIR CONDITIONER

CHECK TENSION OF COMPRESSOR BELT

If the belt is loose, it will slip and will not be able to carry out cooling
properly.
Check the belt tension from time to time. The deflection should be
10 mm (0.4 in) when pressed at a point midway between the drive
pulley (1) and compressor pulley (2) with a finger force of approx.
58.8 N (6 kg).
When the V-belt is new, it will stretch at first, so always adjust it
after 2 or 3 days.

CHECK LEVEL OF REFRIGERANT(GAS)

WARNING
When handling refrigerant gas, always follow local laws and regulations.
The refrigerant used in the cooler is colorless and odorless and does not harm the atmosphere, but if the liquid gets into your
eyes or on your hands, it may cause loss of sight or frostbite, so never loosen any part of the refrigerant circuit.

If the level of the refrigerant (gas) is low, the cooling effect will be
reduced. Run the engine at high idle, and check the flow of the
refrigerant gas (R134a) in the refrigerant circuit through the sight
glass (2) (inspection window) of the receiver (1) when the cooler is
running at high speed.

(A) Correct: No bubbles are included in the flow

(B) Low: Bubbles are included in the flow
(bubbles pass continuously)
(C) None: Colorless, transparent

REMARK
When there are bubbles, the refrigerant gas level is low, so contact your refrigerant dealer to have refrigerant
added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
New Freon R134a is used as the refrigerant.

4 - 44
.

MAINTENANCE SERVICE PROCEDURE

LUBRICATE DOOR HINGE

If the door makes a squeaking noise when it is opened or closed,
spray lubricant in through the split in the hinge bushing.
If the bushing is worn, replace the hinge.

CHECK DOOR LATCH

WARNING
It is quite dangerous if the machine suddenly starts to move during the
inspection work. Stop the engine and operate the parking brake lever to the
LOCK (L) position without fail.

Check
Hold the door open-locked, and check that there is still grease
inside the latch. If the amount of grease is low or there is no more
grease, coat the inside of the latch with grease from portion (1).

REMARK
If there is no more grease inside the latch, the movement will
become poor because of dust inside the latch, and the handle may
be stiff when opening the door.

CHECK DOOR LOCK STRIKER

If wear (A) of the door of lock striker exceeds 0.5 mm (0.02 in),
replace the striker. If it is used as it is, the play will increase and this
may result in breakage of the hinge or door lock.

4 - 45
.

SERVICE PROCEDURE MAINTENANCE

REPLACE DOOR DAMPER

If depth (A) of the groove of door damper rubber (1) is less than 2
mm (0.08 in), replace the damper.
There are 4 dampers: 1 each at the top and bottom on the left and
right doors.

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID

If there is air in the window washer fluid, check the level and add
fluid.
Open the battery cover, check the level of the fluid in window
washer tank (1), and if it is low, add automobile window washer
fluid.
When adding fluid, be careful not to let any dust get in.

4 - 46
.

MAINTENANCE SERVICE PROCEDURE

REPLACE WIPER BLADE

If the blade is damaged, it will not wipe the window clean, so
replace the blade.

REPLACEMENT

FRONT, REAR WIPER

1. Remove screw (1), then remove the blade.
2. Install a new blade, then tighten screw (1) securely.

REAR WIPER
1. Remove E-ring (1).
The blade can then be removed.
2. Install a new blade, then install securely with E-ring (1).

DOOR WIPER
1. It is hooked at portion (A), so move the blade in the direction of
the arrow to remove it.
2. Install the new blade and hook it securely.

4 - 47
.

SERVICE PROCEDURE MAINTENANCE

BLEEDING AIR IN HYDRAULIC SYSTEM

See "OPERATIONS AND CHECKS AFTER STARTING ENGINE (PAGE 3-100)".
Since the engine must be started and the blade must be operated, see OPERATION.

NOTICE
If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder
may cause damage to the piston packing.

1. Bleeding air from cylinders

1) Run the engine at low idle, and extend and retract each cylinder 4 to 5 times, taking care that a cylinder is
not moved to the end of its stroke. (Stop the cylinder approx. 100 mm (3.9 in) short of its stroke end)
2) Next, operate each cylinder 3 to 4 times to the end of its stroke.
3) Finally, operate each cylinder 4 to 5 times to the end of its stroke to completely remove the air.

4 - 48
.

MAINTENANCE SERVICE PROCEDURE

LUBRICATING
1. Lower the work equipment to the ground, then stop the engine.
2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.

Fuel control (1 place)

(1)Decelerator pedal

Steering, directional, gearshift lever rotating link (4 places)

4 - 49
.

SERVICE PROCEDURE MAINTENANCE

CHECK BEFORE STARTING

For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-75)".
Checking with machine monitor
Check coolant level, add coolant
Check fuel level, add fuel
Check water separator, drain water and sediment
Check oil level in engine oil pan, add oil
Check oil level in power train case, add oil
Check brake pedal travel
Check dust indicator
Check oil level in hydraulic tank, add oil
Check electric wiring
Check that lamps light up
Check horn sound
Check backup alarm sound
Check seat belt for wear or damage
Adjust mirror
Adjust joystick
Adjust armrest

4 - 50
.

MAINTENANCE SERVICE PROCEDURE

EVERY 250 HOURS SERVICE

LUBRICATING
1. Lower the work equipment to the ground, then stop the engine.
2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.

(1) Blade lift cylinder support yoke (4 places)

REMARK
These are at the front and rear of the left and right cylinders.

(2) Blade lift cylinder support shaft (2 places)

SIGMADOZER
(3) Blade arm ball joint (1 place)
(4) Brace screw (2 places) (single tilt specification)

SEMI U-DOZER, U-DOZER

(3) Blade arm ball joint (4 places)
(4) Brace screw (2 places) (single tilt specification)

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.

SERVICE PROCEDURE MAINTENANCE

(5) Ripper tilt cylinder bottom pin (2 places)

(6) Ripper lift cylinder bottom pin (2 places)
(7) Ripper tilt cylinder rod end pin (2 places)
(8) Ripper lift cylinder rod end pin (2 places)
(9) Ripper arm pin (front) (2 places)
(10)Ripper arm pin (rear) (2 places)

The illustration on the right shows Giant Ripper (if equipped).

(11) Equalizer bar side shaft (2 places)

(12) Suspension (Equalizer bar center shaft) (1 place)

1) Carry out greasing of the suspension (equalizer bar center shaft) through the grease fittings marked by arrows.
2) Pump the greasing lever up and down 3 to 5 times.

4 - 52
.

MAINTENANCE SERVICE PROCEDURE

CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST

CHECKING
Depress a belt at a mid point between drive pulley (1) and
alternator pulley (2) with a thumb to apply 98 N (10 kg) - pressure,
and when deflection amount (A) remains between 13 mm and 16
mm (0.51 in and 0.63 in), the deflection is within the standard value.

ADJUSTING
1. Remove cover mounting bolts (6) (2 places), and remove the
cover.
2. Loosen bolts and nuts (1), (2), and (5), then turn nut (4) and
adjust the belt tension.
3. After adjusting, tighten bolts and nuts (1), (2), and (5), to secure
alternator (3) in position.
4. Reinstall the cover removed in step 1. Confirm that no part of
the cover touches any moving part of the alternator.

REMARK
Check each pulley for breakage and wear of the V-groove. In particular, check that the V-belt does not touch the
bottom of the V-groove.
If any abnormality is found, ask your Komatsu distributor for replacement of the pulley.
If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.
When adjusting the V-belt, do not press the alternator directly with a bar, but put a wood piece, etc. in-between
them.
If the V-belt has been replaced with a new part, there will be initial elongation, so inspect and adjust it again after
one-hour of operation.

4 - 53
.

SERVICE PROCEDURE MAINTENANCE

CHECK LEVEL OF BATTERY ELECTROLYTE

Carry out this procedure before operating the machine.

WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the
inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion.
The battery generates flammable gas and there is danger of explosion, do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the
electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.

NOTICE
If there is a fear that the battery water may freeze after refilling with purified
water (e.g. commercially available replenishment water for a battery), do
the replenishment before the day's work on the next day.

Inspect the battery electrolyte level at least once a month and

follow the basic safety procedures given below.
Open cover (1), (2) at the rear left side of the machine. The
batteries are installed at (A) part.

WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY

If it is possible to check the electrolyte level from the side of the
battery, check as follows.
1. Use a wet cloth to clean the area around the electrolyte level
lines and check that the electrolyte level is between the
UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.

2. If the electrolyte level is below the midway point between the

U.L and L.L lines, remove cap (3) and add distilled water to the
U.L line.
3. After adding distilled water, tighten cap (3) securely.

REMARK
If distilled water is added to above the U.L. line, use a syringe to
lower the level to the U.L. line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it away with a large
amount of water or consult your Komatsu distributor or battery
maker.

4 - 54
.

MAINTENANCE SERVICE PROCEDURE

WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY

If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Remove cap (3) at the top of the battery, look through the water
filler port (4), and check the electrolyte surface. If the
electrolyte does not reach the sleeve (5), add distilled water so
that the level reaches the bottom of the sleeve (UPPER LEVEL
line) without fail.
(A) Suitable level: Electrolyte level is up to bottom of sleeve,
so surface tension causes electrolyte
surface to bulge and poles appear bent.
(B) Low: Electrolyte level is not up to bottom of sleeve, so
poles appear straight and not bent.
2. After adding distilled water, tighten cap (3) securely.

REMARK
If water is added to above the bottom tip of the sleeve, use a pipette
to remove electrolyte. Neutralize the removed electrolyte with
sodium bicarbonate, then flush it away with a large amount of
water. If necessary, contact your Komatsu distributor or your
battery maker.

WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL

If it is possible to use an indicator to check the electrolyte level, follow the instructions given.

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SERVICE PROCEDURE MAINTENANCE

CHECK BRAKE PERFORMANCE

WARNING
If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately.

NOTICE
Do not place the joystick in the 1st speed position.
Otherwise, it will cause damage to the machine.

Before starting the engine, check that the area around the machine is safe, then do as follows:
1. Start the engine.
2. After completing the warm-up operation, set fuel control dial (3) to the SLOW position.
3. Set work equipment lock lever (1) to the FREE position then
operate blade control lever (6) and ripper control lever (7) to
raise the blade and ripper.
Leave the work equipment lock lever (1) in the FREE position.
4. Set parking brake lever (2) to the FREE position.

5. Depress brake pedal (5), set joystick (4) in FORWARD, then

press the shift up button to enter 2nd speed.
6. Operate fuel control dial (3) and gradually raise the engine
speed to full throttle. (Keep the brake pedal depressed.)
7. Check that the machine does not move. This indicates that
brake performance is normal.

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MAINTENANCE SERVICE PROCEDURE

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL

1. Open the engine side cover on the left side of the chassis.
2. Remove dipstick (G) and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into filler pipe, then remove it.
4. The oil should be between the H and L marks on dipstick (G).
If the oil is below the L mark, add oil through the dipstick
insertion port.

5. If the oil is above the H mark, open inspection cover (2) in the
center of the bottom face of the power train case, drain the
excess oil from engine damper drain plug (P) (this can be seen
towards the front of the machine from the inspection window),
then check the oil level again.

REMARK
Check the oil level while the engine is stopped.
If the machine is inclined, set it in a level position before checking the oil level.

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SERVICE PROCEDURE MAINTENANCE

EVERY 500 HOURS SERVICE

Maintenance for every 250 hours should be performed at the same time.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
(including engine by-pass filter cartridge)

WARNING
The oil is at high temperature after the engine has been operated, so never change the oil immediately after finishing operations.
Wait for the oil to cool down before changing it.

Refill capacity: 50 liters (13.2 US gal)

Prepare a socket wrench and filter wrench.

1. Remove the covers at the bottom left at the front of the

machine and on the side face, and put a container directly
underneath to catch the drained oil.
2. Remove drain plug (1) and loosen drain valve (2) slowly to
avoid getting oil on yourself, and drain the oil.
Take care not to loosen drain valve (2) so much that the
stopper pin in the valve is distorted.
Tightening torque for drain plug (1) : 68.6 ± 9.81 Nm (7 ± 1
kgm, 50.6 ± 7.2 lbft)
Tightening torque for drain valve (2): 63.7 ± 14.7 Nm (6.5 ± 1.
5 kgm, 47.0 ± 10.8 lbft)

3. Check the drained oil, if there is excessive metal particles or

foreign material, contact your Komatsu distributor.
4. Tighten drain valve (2), then tighten plug (1).

5. Open up the left engine side cover, remove the two bolts on the
inside and open the lower cover outward on the intermediate
hinges.
6. Using the filter wrench, turn engine oil filter cartridge (3) to the
left and remove it.

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MAINTENANCE SERVICE PROCEDURE

7. Clean the filter holder, fill the new filter cartridge with engine oil,
coat the packing surface and thread with engine oil (or coat it
thinly with grease), then install the filter cartridge.
8. When installing the filter cartridge, bring the packing surface
into contact with the filter holder, then tighten a further 3/4 to 1
turn.

9. After replacing the filter cartridge, add engine oil through oil
filler port (F) until the oil level is between the H and L marks on
the dipstick.

10. Run the engine at idling for a short time, then stop the engine, and check that the oil level is between the H and
L marks on the dipstick. For details, see "CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL (PAGE 3-79)".
Even if the machine has not been operated for 500 hours, the oil and filter cartridge must be replaced when the
machine has been operated for 12 months.
In the same way, even if the machine has not been operated for 12 months, the oil and filter cartridge must be
replaced when the machine has been operated for 500 hours.

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SERVICE PROCEDURE MAINTENANCE

REPLACE POWER TRAIN OIL FILTER ELEMENT, STEERING LUBRICATING OIL FILTER ELEMENT

WARNING
Before opening the filter cases, depress the brake pedal several times to release the pressure, then lock the brake pedal. If there
is still pressure inside the filter, the oil may spurt out.

1. Remove the floor cover on right side fender.

(1)Power train oil filter
(2)Steering lubrication oil filter

2. Remove bolts (3), pull up cover (4), then take out element (5).
3. Clean inside of the case and the removed parts, then install a
new element.
Replace the O-ring with a new one.

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MAINTENANCE SERVICE PROCEDURE

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

WARNING
There is danger that oil may spurt out under internal pressure, so stand to the side, and gradually turn the plug to release internal
pressure before removing the plug.

1. Place the machine on a horizontal place.

2. Remove oil level plug (G) and check whether the final drive
case is filled with oil to lower edge of the plug hole.

3. If the oil level is still too low, add oil through oil filter plug hole
(F) until the oil overflows.
Before removing oil plug (F), remove all the mud and dirt from
around oil filler plug (F). Be careful not to let any dirt or sand get
in when adding oil.

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SERVICE PROCEDURE MAINTENANCE

REPLACE FUEL PRE-FILTER CARTRIDGE

WARNING
After the engine has been operated, all parts are at high temperature, so do not replace the filter immediately. Wait for all parts
to cool down before starting the operation.
High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before
replacing the filter.
Do not bring any fire or flame close.
Be careful when opening the air bleed plug in the fuel filter head. It is still under pressure, so fuel may spurt out.

NOTICE
Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter
cartridge, always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection
pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection
system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is
stuck to any part, use fuel to wash it off completely.

Container to catch the oil

Prepare a filter wrench

1. Close the fuel valve.

2. Set a container under the fuel pre-filter cartridge to catch the
oil.
3. Remove water separator (1) to inspect, using a filter wrench. If
any damage is found, replace it with a new one.

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MAINTENANCE SERVICE PROCEDURE

4. Using a filter wrench, turn filter cartridge counterclockwise to

remove it.
5. Clean water separator (1) and remove seal (2).
Coat new seal (2) with clean oil and install it.
6. Install water separator (1) to new filter cartridge (3).
(Tightening torque: 10 Nm {1 kgm, 7.2 lbft})
7. Check that drain plug (4) at the bottom of the water separator
is securely tightened.
Tightening torque: 0.2-0.45 Nm {0.02-0.046 kgm, 0.1-0.3 lbft}

8. Clean the filter holder, fill the new filter cartridge with clean fuel, coat the packing surface thinly with oil, then
install to the filter holder.

NOTICE
When adding fuel, do not remove cap (B). Always add fuel from the 8
small holes (A) on the dirty side.
After adding 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 adding fuel. Be careful not to let dirt or dust get into center
portion on the clean side.

9. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4
of a turn.
If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
When tightening with a filter wrench, be extremely careful not to dent or damage the filter.
10. Open the fuel valve, start the engine, and run the engine for approx. 10 minutes at low idling until the engine
speed stabilizes. Check for any leakage of oil from the filter cartridge seal surface or transparent cup, and check
for any sucking in of air.

NOTICE
When replacing the fuel main filter cartridge, replace the filter cartridge, then bleed the air. For details, see "REPLACE FUEL MAIN
FILTER CARTRIDGE (PAGE 4-64)" in the Operation and Maintenance Manual.
Do not fill the fuel main filter cartridge with fuel.

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SERVICE PROCEDURE MAINTENANCE

EVERY 1000 HOURS SERVICE

Maintenance for every 250 and 500 hours service should be carried out at the same time.

REPLACE FUEL MAIN FILTER CARTRIDGE

WARNING
After the engine has been operated, all parts are at high temperature, so do not replace the filter immediately. Wait for all parts
to cool down before starting the operation.
High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before
replacing the filter.
Do not bring any fire or flame close.
Be careful when opening the air bleed plug in the fuel filter head. It is still under pressure, so fuel may spurt out.

NOTICE
Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter
cartridge, always use a genuine Komatsu part.
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection
pump and nozzle.
If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection
system. Always avoid using substitute parts.
When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is
stuck to any part, use fuel to wash it off completely.

Container to catch the oil

Prepare a filter wrench

1. Set the container under the filter cartridge to catch the drained
oil.
2. Close valve (1) of fuel strainer part.

3. Using a filter wrench, turn filter cartridge (2) counterclockwise

to remove it.

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MAINTENANCE SERVICE PROCEDURE

NOTICE
Do not fill the fuel filter cartridge with fuel.
Remove cap (B) and install the fuel filter.

4. Clean the filter holder, coat the packing surface of the new filter
cartridge thinly with oil, then install the filter cartridge to the filter
holder.

5. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4
of a turn.
If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the
filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
6. After filter cartridge (2) has been replaced with a new one, bleed air from the cartridge in reference to
"PROCEDURE FOR BLEEDING AIR (PAGE 3-153)".

REMARK
When only the filter cartridge is replaced, it is suffficient that air bleeding is carried out for the filter head alone. But
when the fuel piping is removed, air bleeding should also be carried out for the injection pump air-bleeding valve.

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SERVICE PROCEDURE MAINTENANCE

REPLACE FUEL TANK BREATHER ELEMENT

1. Remove nut (2) of breather assembly (1) at the top surface of
the fuel tank, then remove cover (3).
2. Replace breather element (4) with a new part.
3. Install cover (3) and nut (2).

REPLACE HYDRAULIC TANK BREATHER ELEMENT

1. Remove nut (2) of breather assembly (1) at the top of the
hydraulic tank, then remove cover (3).
2. Replace breather element (4) with a new part.
3. Install cover (3) and nut (2).

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MAINTENANCE SERVICE PROCEDURE

CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP
STRAINER)

WARNING
The oil is at high temperature immediately after operations, so wait for the temperature to go down before starting the
operation.
The undercover is heavy. Do not go directly under the cover when opening or closing it. When removing bolts (5), carry out the
operation at the rear of the point immediately under the cover so that it is possible to escape at any time.
Prepare the following.

Refill capacity: 90 liters (23.78 US gal)

1. Remove drain cover (1) on the left side at the bottom of the
power train case, pull out drain hose (2) from the takeoff port,
then loosen drain plug (P1) and drain the oil.
After draining the oil, tighten drain plug (P1).
Do not remove drain plug (P1).

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SERVICE PROCEDURE MAINTENANCE

2. Remove inspection cover (3) in the undercover at the bottom

rear of the machine as follows.
1) Remove 2 bolts (4) at the front (front of machine).
2) Hold cover (3) in position and gradually remove 2 bolts (5) at
the rear (rear of machine). (Rain water may flow out when
doing this.)
3) Lower cover (3) gradually to open it. (The front of the cover
is attached by a hinge.)
If you look up, you can see the strainer at portion (P).

(F)Front of the machine

3. Remove drain plug (P2) in the strainer cover, and drain the oil
(approx. 4 liters (1.06 US gal)) collected inside the piping.
4. Loosen mounting bolt (6) of the power train strainer, and
remove cover (7).

5. Remove spring (8), then remove strainer (9).

6. Remove any dirt stuck to strainer (9), then wash it in clean
diesel oil or flushing oil. Wash the removed parts and the inside
of the case at the same time.
7. Loosen mounting bolt (10) of the scavenging pump strainer,
then remove cover (11).

8. Remove strainer (12).

9. Remove any dirt stuck to strainer (12), then wash it in clean diesel oil or flushing oil. Wash the removed parts
and the inside of the case at the same time.
10. Install the strainers in their original position.
11. Replace the power train oil filter element. For details, see "REPLACE POWER TRAIN OIL FILTER ELEMENT,
STEERING LUBRICATING OIL FILTER ELEMENT (PAGE 4-60)".

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MAINTENANCE SERVICE PROCEDURE

12. Refill the specified quantity of oil through oil filler (F).
13. After filling with oil, check that the oil is at the specified level.
For details, see "CHECK OIL LEVEL IN POWER TRAIN
CASE, ADD OIL (PAGE 3-81)".
If the spring or strainer are damaged, replace them with a new
part.

CHECK, CLEAN FUEL STRAINER

1. Tighten valve (1).
2. Remove cap (2), and wash the strainer and strainer case.
The strainer forms one unit with the cap.
3. After checking and cleaning, set the strainer in the case, then
tighten cap (2).
4. After installing, open valve (1).

CHECK FOR LOOSE ROPS MOUNT BOLTS

Check for loose and damaged bolts. If any loose bolt is found, tighten to a torque of 1180 to 1470 Nm (120 to 150
kgm, 868 to 1,085 lbft).
If any damaged bolt is found, replace the bolt with a genuine Komatsu bolt.

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SERVICE PROCEDURE MAINTENANCE

CHECK HOSE CLAMPS BETWEEN AIR CLEANER AND TURBOCHARGER, TURBOCHARGER AND AFTERCOOLER,
AFTERCOOLER AND ENGINE

Contact your Komatsu distributor to have the tightening portions checked.

1. Check hose clamps between air cleaner and turbocharger
Check that the hose is inserted is at least 40mm. Check that
the clamps are tightened.
Tightening torque: 8.83 ± 0.5Nm
(0.9 ± 0.05kgm, 6.5 ± 0.4lbft)

2. Check hose clamps between turbocharger and aftercooler

Check that the hose is inserted is at least 80 mm. Check that
the clamps are tightened.
Tightening torque: 24.0 ± 1.0 Nm
(2.45 ± 0.1kgm, 17.7 ± 0.7lbft)

3. Check hose clamps between aftercooler and engine

Check that the hose is inserted is at least 80 mm. Check that
the clamps are tightened.
Tightening torque: 24.0 ± 1.0 Nm
(2.45 ± 0.1kgm, 17.7 ± 0.7lbft)

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MAINTENANCE SERVICE PROCEDURE

REPLACE CHARGE FILTER ELEMENT

1. Remove inspection cover (1).

2. Loosen mounting bolt (2) and remove filter cover (3).

3. Remove drain plug (P) (which can be seen from under the
fender) and drain the oil.
4. Remove spring (4), then take out element (5) .
5. Clean the removed parts and the inside of filter case (6), then
install a new element.
Use a genuine Komatsu element.
6. Install inspection cover (3) with bolt (2).

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SERVICE PROCEDURE MAINTENANCE

EVERY 2000 HOURS SERVICE

Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time.

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK
STRAINER

WARNING
The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before changing
the oil.
When removing the oil filler cap (F), turn it slowly to release the internal pressure, then remove it carefully.

Refill capacity: 130 liters (34.35 US gal)

1. Lower the blade and ripper on the ground securely, stop the
engine and slowly turn the cap of oil filler (F) to release the
internal pressure. Then, remove the cap.

2. Remove drain plug (1) at the bottom of the tank and loosen
drain valve (2). After draining the oil, tighten drain plug (1) and
drain valve (2). When loosening drain valve (1), be careful not
to get oil on yourself.

3. Remove bolts (3), then remove cover (4) and take out the
element.
4. Clean the inside of case and removed parts and install a new
element.

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MAINTENANCE SERVICE PROCEDURE

5. Remove bolts (5), then remove cover (6) and take out the
strainer.
6. Wash the strainer in clean diesel oil or flushing oil.
7. Install the strainer to its original position.
8. Add oil through oil filler port (F) to the specified level.

9. After adding oil, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN HYDRAULIC
TANK, ADD OIL (PAGE 3-83)".

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SERVICE PROCEDURE MAINTENANCE

CHANGE OIL IN FINAL DRIVE CASE

WARNING
The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting
the operation.
There is danger that oil spouts out due to the internal pressure. When removing the plug, work from the side, turn the plug
slowly to release the internal pressure, and remove it carefully.

Refill capacity: 40 liters (10.57 US gal)

1. Remove oil filler plug (F), then remove drain plug (1) and level
plug (G), and drain the oil.
Remove all the mud and dirt from around oil filler plug (F)
before removing it. Be careful not to let any dirt or sand get in
when adding oil.

2. After draining the oil, tighten the drain plug (1).

3. Remove level plug (G), refill oil from oil filler plug hole (F) until
the oil overflows the level plug hole.
After refilling, tighten the plugs.

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MAINTENANCE SERVICE PROCEDURE

CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER

WARNING
The oil is at high temperature immediately after the machine has been operated.Wait for the oil to cool down before carrying
out maintenance.
The undercover is heavy. Do not go directly under the cover when opening or closing it. When removing bolts (4), carry out the
operation at the rear of the point immediately under the cover so that it is possible to escape at any time.

Refill capacity: 1.5 liters (0.40 US gal)

1. Open the engine side cover (1) at the left of the machine; you
can see gauge (G).

2. Remove the undercover (2) at the bottom rear of the chassis as

follows.
1) Remove 2 bolts (3) toward the front of the chassis.

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SERVICE PROCEDURE MAINTENANCE

2) Hold cover (2) and gradually remove 2 bolts (4) at the rear
of the chassis. (Be careful when doing this. Rain water may
run out.)
3) Lower cover (2) slowly and open it. Drain plug (P) can be
seen at the top.

(F)Front of the machine

3. Remove dipstick (G), then remove drain plug (P) and drain the
oil.
After draining the oil,tighten drain plug (P).
4. Add oil through the holder of dipstick (G). After adding the oil,
insert dipstick (G).
5. Remove any dirt or dust stuck to breather (5), then wash with
clean diesel oil or flushing oil. If it cannot be cleaned
completely, replace with a new part.
6. Install undercover (2), then close engine side cover (1) on the
left side of the machine.

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MAINTENANCE SERVICE PROCEDURE

CHECK PIVOT BEARING OIL LEVEL, ADD OIL

1. Remove plug (1).
When removing plug (1), be careful not to let dirt or dust get it.

2. Check that the oil is up to oil level (2) in the diagram.

If the oil level is low, add oil through the hole for plug (1).
(B): 25mm (1inch)

CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL
1. Remove bolts (1), then remove cover (2).
When removing the cover, be careful not to let dirt or sand get
in.
2. Loosen the plug and confirm that the internal pressure is
released.

Insert a scale and check that the oil level is 70 to 80 mm (2.8 to 3.2
in) from the bottom edge of the inspection port.
If the oil is insufficient, add oil.

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SERVICE PROCEDURE MAINTENANCE

CHECK ALTERNATOR
Contact your Komatsu distributor to have the alternator checked.
If the engine is started frequently, have this inspection carried out every 1000 hours.

CHECK ENGINE VALVE CLEARANCE, ADJUST

Special tools are needed for inspection and maintenance, so contact your Komatsu distributor.

CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)

WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion, which will lead to
serious injury or damage. When handling the accumulator, always do as follows.
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 carrying out the operation. In addition, loosen the bolts slowly when carrying out
the operation.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it or weld it.
Do not hit it, roll it, or subject it to any impact.
When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work
carried out.

NOTICE
If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it will become impossible to release
the remaining pressure inside the hydraulic circuit if a failure occurs on the machine.

FUNCTION OF ACCUMULATOR
The accumulator stores the pressure in the control circuit. Even
after the engine is stopped, the control circuit can be operated, 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.

The accumulator is installed to the position shown in the diagram

on the right.

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MAINTENANCE SERVICE PROCEDURE

CHECKING FUNCTION OF ACCUMULATOR

CAUTION
When carrying out the inspection, check first that there is no person or obstacle in the surrounding area.

Check the nitrogen gas charge pressure as follows.

1. Stop the machine on firm, level ground.
2. Set the parking brake lever to the LOCK position (L).

3. Raise the work equipment (blade) to the maximum height.

Carry out Steps 4 - 6 within 15 seconds.

When the engine is stopped, the pressure in the accumulator gradually goes down. For this reason, the check can
only be carried out immediately after the engine is stopped.

4. Keep the work equipment raised to the maximum height, then

turn the starting switch to OFF position (A) to stop the engine.

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SERVICE PROCEDURE MAINTENANCE

5. Turn the starting switch to the ON position (B).

6. Set the work equipment lock lever to the FREE position (F),
then operate the blade control lever fully in the LOWER
direction and check that the work equipment is completely in
contact with the ground.

7. If the work equipment goes down under its weight and contacts
the ground, the accumulator is normal.
If the work equipment does not go down or stops in midway,
the charged pressure of the gas in the accumulator for the
hydraulic circuit has probably dropped.
Please contact your Komatsu distributor for inspection.

8. This completes the inspection. After completing the inspection, set the work equipment lock lever to the LOCK
position and turn the starting switch to the OFF position.

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MAINTENANCE SERVICE PROCEDURE

METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT

1. Lower the work equipment to the ground.
2. Set the parking brake lever and work equipment lock lever to the LOCK position.

Carry out Steps 3 - 5 within 15 seconds.

When the engine is stopped, the pressure in the accumulator gradually goes down. For this reason, the release
can only be carried out immediately after the engine is stopped.

3. Stop the engine.

4. Turn the starting switch to the ON position (B).

5. Set the work equipment lock lever to the FREE position (F),
then operate the blade control lever and ripper control lever
fully to the front, rear, left, and right to release the pressure in
the hydraulic circuit.

6. Set the work equipment lock lever to the LOCK position and turn the starting switch to the OFF position.

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SERVICE PROCEDURE MAINTENANCE

EVERY 4000 HOURS SERVICE

Maintenance for every 250, 500, 1000 and 2000 hours service should be carried out at the same time.

REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)

Replace the accumulator every 2 years or every 4000 hours, whichever comes sooner.

WARNING
The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion, which will lead to
serious injury or damage. When handling the accumulator, always do as follows.
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 carrying out the operation. In addition, loosen the bolts slowly when carrying out
the operation.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it or weld it.
Do not hit it, roll it, or subject it to any impact.
When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work
carried out.

If operations are continued after the performance of the

accumulator has dropped, it will be impossible to release the
remaining pressure in the hydraulic circuit if there should be a
failure on the machine. Please ask your Komatsu distributor to
replace the accumulator.

The accumulator is installed to the position shown in the diagram

on the right.

CHECK WATER PUMP

Check for oil and coolant leakage, or clogging of the drain hole. If any abnormality is found, contact your Komatsu
distributor for disassembly, repair, or replacement.

CHECK STARTING MOTOR

Contact your Komatsu distributor to have the starting motor checked.
If the engine is started frequently, have this inspection carried out every 1000 hours.

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MAINTENANCE SERVICE PROCEDURE

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER

Check for any looseness in the high-pressure clamp mounting bolts (1) to (15) in the drawing in the illustrations
below. Check visually and feel with your finger to check that the rubber has not hardened. If there is any problem,
the problem part must be replaced. Contact your Komatsu distributor for part replacement.

NOTICE
If the engine continues to be used when there are loose bolts, hardened rubber, or missing parts, there is danger of damage or
breakage occurring due to vibration and wear at the connections of high-pressure piping. Always check that the proper
high-pressure piping clamps are correctly installed.

4 - 83
.

SERVICE PROCEDURE MAINTENANCE

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER

Fuel spray prevention caps (1) - (16) and fuel spray prevention cover (17) are protective parts installed to prevent
fire caused by fuel leaking and spraying out on to high temperature parts of the engine. Check visually that there
are no missing caps or loose bolts, and feel with your finger to check that the rubber has not hardened. If there is
any problem, the problem part must be replaced. Contact your Komatsu distributor for part replacement.

4 - 84
.

MAINTENANCE SERVICE PROCEDURE

CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)

Check after the first 4000 hours, and every 1000 hours after that.
Preparation
Wipe off all the mud that is stuck around portions (A) - (L) of the
work equipment and frame to make it easier to carry out the check.

Visual check
Carefully check the base material of the steel casting and welding
at portions (A) - (L), and check that there is no damage.
If any cracks or other damage is found, repair them.

Contact your Komatsu distributor for details of the repair

procedure.

4 - 85
.

SERVICE PROCEDURE MAINTENANCE

EVERY 8000 HOURS SERVICE

Maintenance for every 10, 100, 250, 500, 1000, 2000, and 4000 hours of service should be performed at the same
time.

REPLACE HIGH-PRESSURE PIPING CLAMPS

Contact your Komatsu distributor to have the engine high-pressure clamps replaced.

REPLACE FUEL SPLAY PREVENTION CAPS

Contact your Komatsu distributor to have the fuel spray prevention cap replaced.

4 - 86
.

5-1
.

SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS
D275AX-5E0
Item Unit Semi Reinforced
U-tiltdozer
U-tiltdozer sigmadozer
50,710 (*1) 50,775 (*2) 51,400(*3)
Operating weight (without operator) kg (lb)
(111.816) (111.959) (113.337)
Blade unit weight kg (lb) 6,750 (14,884) 7,676 (16,926) 8,300 (18.302)
4,462 (9,839) 3,600 (7,938)
Ripper unit weight kg (lb)
(Multi-shank) (Giant)
Name of engine - KOMATSU SAA6D140E-5 diesel engine
Engine horsepower kW(HP)/rpm 336(451)/2,000
A Overall length mm (ft in) 8,905 (29ft 3in) 9,595 (31ft 6in) 8,995 (29ft 6in)
B Overall hight mm (ft in) 3,990 (13ft 1in)
C Overall width mm (ft in) 4,300 (14ft 1in) 4,615 (15ft 2in) 4,440 (14ft 7in)
Travel speed Forward km/h (MPH) 3.8/6.7/11.2 (2.4/4.2/7.0)
(1st/2nd/3rd) Reverse km/h (MPH) 4.9/8.7/14.9 (3.0/5.4/9.3)

*1: Semi U-tiltdozer, multi-shank ripper, ROPS, cab, air conditioner

*2: U-tiltdozer, Giant ripper, ROPS, cab, air conditioner
*3: Reinforced sigmadozer, Giant ripper, ROPS, cab, air conditioner

5-2
.

6-1
.

GENERAL PRECAUTIONS ATTACHMENTS, OPTIONS

GENERAL PRECAUTIONS
PRECAUTIONS RELATED TO SAFETY
If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the
machine, but will also cause problems with safety.
When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distributor
first.
If you do not contact Komatsu, we cannot accept any responsibility for any accidents or failures.

WARNING
General precautions
Read the instruction manual for the attachment carefully, and do not use the machine before you understand the operation
method completely.
If you lose the instruction manual, be sure to order another copy from your Komatsu distributor.
To prevent serious personal injury caused by misoperation, place your foot on the pedal only when operating the pedal.
Precautions for removal and installation
When removing or installing an attachment, observe the following items and work safely.
Select a firm, level surface when installing or removing an attachment.
When working in cooperation with one or more other workers, decide signs and observe them when carrying out the operation.
When carrying a heavy part (25 kg (55 lb) or more), use a crane.
When removing a heavy part, always place a support in position before removing it.
When lifting a load with a crane, be particularly careful of the center of gravity.
It is dangerous to carry out operations when the load has been raised by a crane. Always lower the load onto a stand and check
that it is safe.
When leaving an attachment removed or installing it, place it in a stable position to prevent it from falling over.
Never go under a load raised by a crane.
Always stand in a place which is safe even if the load should fall.

NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified person.
For details of removal and installation operations, contact your Komatsu distributor.

6-2
.

ATTACHMENTS, OPTIONS SELECTION OF TRACK SHOE

SELECTION OF TRACK SHOE

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

METHOD OF SELECTING SHOES

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

Category Use Precautions when using Track shoe width

Bedrock, This shoe can be used for a wide range of work from crushed
A normal rock to general civil engineering work such as reclamation of 610 mm (24 in)
soil residential land. There is no particular limit to its use.
Use this shoe for general soil, such as where the main work is
scraper work and pusher work, reclaiming land for golf courses, or
Normal
B stripping the overburden for coal mines. This shoe cannot be 610 mm (24 in)
soil
used on bedrock. On jobsites where there are rocks in the soil, be
careful to avoid letting the machine mount the rocks.
Use this shoe on soft ground where the shoe in category B sinks
710 mm (28 in)/
C Soft soil into the ground. Do not use this shoe on jobsites where there are
760 mm (29.9 in)
rocks in the soil.

6-3
.

PROCEDURE FOR SELECTING RIPPER POINT ATTACHMENTS, OPTIONS

PROCEDURE FOR SELECTING RIPPER POINT

REMARK
A symmetrical ripper point is suited to a terrain of hard rocks because it recovers penetrability by turning the point
after the penetrability drops due to its worn tip.
Ripper points usually lose their hardness when they undergo intense heat generated by a contact with rocks
during the use. In this respect, red ripper points are suited to a terrain of hard rocks where those others are likely
to slip during the use, because red ones are made of materials whose hardness less lowers under intense heat,
compared with yellow ripper points.
Where an amount of wear on a ripper point is limited, a heat- originated (thermal) crack on the point surface is
not readily removed, and the point itself can break with the crack as a starting point. For this reason, ripper points
for limestone are suited to a jobsite where they are comparatively free of wear.

6-4
.

ATTACHMENTS, OPTIONS EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER

EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER

BLADE CONDITION

SINGLE TILT
Operate single/dual tilt selector switch to the SINGLE position,
then operate the tilt.
Applicable operation
Normal operations

DUAL TILT
Operate single/dual tilt selector switch to the DUAL position, then
operate the tilt.
Applicable operation
Side cutting operations (high places)
Horizontal dozing operations form side slope (rough ground)
Ditching work

REMARK
Use the dual tilt operation for normal operation of the sigmadozer.

6-5
.

EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER ATTACHMENTS, OPTIONS

R PITCH (PITCH BACK)

Keep the pitch button pushed in and operate the left tilt.
Applicable operation
Hauling
Dozing soft soil (filling)
Leveling operations (spreading)

S PITCH (STANDARD)
Normal operations
Applicable operation
Normal operations

F PITCH (PITCH DUMP)

Keep the pitch button pushed in and operate the right tilt.
Applicable operation
Digging natural ground and bed-rock (digging hard soil)
Pushing soil over cliffs
Pushing-up soil
(Reduces spillage of soil over the top surface of the blade, and
reduces amount of soil carried back)

REMARK
With the sigmadozer, the maximum rear pitch condition is the normal pitch posture (straight pitch).
If the single tilt is being used in this condition, it is impossible to operate the left tilt from the horizontal position, so
use the dual tilt.

6-6
.

ATTACHMENTS, OPTIONS EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER

DOZING WORK

DOZING ON LEVEL GROUND, OR DOWNHILL

NATURAL GROUND, BEDROCK

WARNING
If you feel that the situation is dangerous when dumping the soil, for safety reasons, use two movements to push the soil over the
edge.

1. Dig with the FORWARD PITCH (1), and when the load on the blade is approx 80%, return to STRAIGHT PITCH
(2) and continue digging (A).
2. Set to REAR PITCH (3) which gives a larger load, and haul the soil (B).
Adjust the cutting angle to the most effective angle for rolling the soil.
3. Use FORWARD PITCH (1) to dump the soil (C).

FILLING, SOFT SOIL

Carry out digging in R pitch or S pitch, and haul in R pitch.

REMARK
If the digging is carried out in R pitch, there is no sudden digging
into the soil, and the operation can be carried out smoothly.

6-7
.

EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER ATTACHMENTS, OPTIONS

HARD SOIL (HARD CLAY, SHALE, ETC.)

If digging is carried out in F pitch, and the chassis is raised and the
blade is tilted, the end bit will dig in better.

6-8
.

ATTACHMENTS, OPTIONS EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER

PUSHING-UP SOIL

1. Dig (A) with STRAIGHT PITCH (1).

When digging gradually (A), use REAR PITCH (2).
If the ground is hard, use FORWARD PITCH (3).
2. Haul (B) with REAR PITCH (2).
If there is any spillage of soil over the top of the blade, change to STRAIGHT PITCH (1).
3. Dump the soil (C) with FORWARD PITCH (3).
This dumps the soil more effectively, and less soil is carried back.

6-9
.

EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER ATTACHMENTS, OPTIONS

LEVELING (SPREADING) OPERATION

Carry out this operation with R itch.
When carry out this operation with R pitch, the end bit does not dig
in, and the ground can be leveled ( or the soil can be spread
smoothly.)

REMARK
If the tilt cylinder is moved completely to the end of its stroke, the
tilt operation cannot be carried out on one side, so move the
cylinder back slightly from the end of its stroke to the S pitch
position.

DITCHING OPERATION
If the dual tilt is used, the digging width becomes smaller and a
deeper ditch can be dug.
If R pitch is used, the digging can be carried out gradually, and this
reduces the unevenness.

BOULDER RAISING OPERATION

Because the dual tilt greatly increases the amount of tilt, the blade
can dig in deep and hook under the boulder. In addition, the
operating stroke is large, so operations to raise boulders can be
carried out effectively.

(D): Dual tilt

(S): Single tilt

6 - 10
.

ATTACHMENTS, OPTIONS EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER

SIDE-CUTTING OPERATIONS
Carry out this operation in R pitch, and set the end face of the end
bit in contact with the rock face to carry out cutting.

REMARK
With the dual tilt it is possible to increase the amount of tilt and to
carry out side-cutting operations on higher walls.

HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)

The dual tilt can give a larger amount of tilt, so when dozing from
a side slope, this is effective because the chassis becomes
horizontal after a short digging distance.

6 - 11
.

SHOE SLIP CONTROL ATTACHMENTS, OPTIONS

SHOE SLIP CONTROL

MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)
Press each mode switch to turn it ON or OFF and to select the mode.
For details of setting the mode to use, see "EFFECTIVE USE OF MODE SELECTION SYSTEM (PAGE 3-124)".

The economy mode, reverse slow mode, and shoe slip control mode can be used independently or in
combination.

(1) Shoe slip control switch (2) Rock selection mode selector switch

SHOE SLIP CONTROL SWITCH

This switch (1) is used for ripping operations.
When it is switched ON, the lamp lights up.

NOTICE
If the shoe slip control is switched ON, the rock selection mode is
automatically set to [3], so switch the rock selection mode to match the
type of rock.

6 - 12
.

ATTACHMENTS, OPTIONS SHOE SLIP CONTROL

ROCK SELECTION MODE SELECTOR SWITCH

Using this switch (2) during ripping operations, turn the shoe slip
control ON and select mode [1] - [5] according to the shoe slip
ratio.
The lamp for the selected mode lights up.

6 - 13
.

SHOE SLIP CONTROL ATTACHMENTS, OPTIONS

EFFECTIVE USE OF MODE SELECTION SYSTEM

(1) Lock up mode switch (4) Shoe slip control switch

(2) Economy mode selector switch (5) Rock selection mode selector switch
(3) Reverse slow mode selector switch

Selecting mode to match the type of work and quality of rock and soil makes to perform operations effectively.
The condition when all the mode selection switches are off is called the standard mode.
Only the reverse slow mode can be selected in combination with the lock-up mode.
The economy mode, reverse slow mode, and shoe slip control mode can be used independently or in combination.

Dozing Ripping
Lock up Economy Reverse slow Shoe slip
mode mode mode control
{ {
{ { {

{: Possible to use : Compound use not possible

6 - 14
.

ATTACHMENTS, OPTIONS SHOE SLIP CONTROL

SELECTION OF MODE

DOZING OPERATIONS

LOCK UP MODE
By using the lock up mode, the travel speed increases, the
operating efficiency is improved, and the fuel consumption is also
reduced.
Speed ranges that can be used: All speed ranges
Applicable operations: Dozing loose material (suitable for
long-distance hauling operations)
When the lock up mode is turned ON, direct drive or torque
converter drive are automatically selected according to the load.

(Example)
Slot dozing operations

Hillside dozing operations

REMARK
If dozing operations are carried out on a slope of more than 15
°, the lock-up tends to be canceled, so operations are easier to
carry out in the standard mode.
For normal ripping operations, if the lock-up mode is used, the
lock-up will switch repeatedly between ON and OFF, so use the
standard mode or shoe slip control mode.
Even with ripping operations, if the ground is extremely soft, the
lock-up mode can be used.

(1)Quality of earth and sand

6 - 15
.

SHOE SLIP CONTROL ATTACHMENTS, OPTIONS

ECONOMY MODE
Using the economy mode makes it possible to reduce wasteful
shoe slippage and to reduce the fuel consumption.
Speed ranges that can be used: F1
Applicable operations: Hauling after ripping, dozing blasted
rock, smoothing.

When the economy mode is turned ON, it is automatically set to [1].

Carry out dozing operations in this condition, then set to [2] and carry out operations. From this test, select the
matching that gives power and low shoe slip ratio (frequency of deceleration operation).
Mode [1] is set to approx. 90% of full power and mode [2] is set to approx 70%.
(Example)
Fine leveling operations

Ripping and dozing operations

REMARK
If the shoe slip control switch is turned ON and the ripper is lowered during dozing operations in the standard
mode, the system will enter the shoe slip control mode. If this happens, return to the N position, set the speed
range to F1, and this will return to the standard mode.
If the economy mode and shoe slip control switches are turned ON and the ripper is lowered during dozing
operations in the economy mode, the system will enter the shoe slip control mode. If this happens, return to the
N position, set the speed range to F1, and this will return to the standard mode.

6 - 16
.

ATTACHMENTS, OPTIONS SHOE SLIP CONTROL

RIPPING OPERATIONS

SHOE SLIP CONTROL

This makes it possible to reduce the frequency of operation of the
decelerator pedal by the operator, and contributes to reduction in
operator fatigue. It also prevents wasteful shoe slippage, improves
the service life of the undercarriage, and reduces fuel
consumption.
Speed ranges that can be used: F1
Applicable operations: Ripping

In normal ripping operations, the operator uses the decelerator pedal to control the engine speed while carrying out
ripping. If the shoe slip control is turned ON, the shoe slip control system aids the operator in carrying out this
control.
When the shoe slip control switch is turned ON, the rock selection
mode is automatically set to [3].
Carry out operations in this condition, and if the shoe slip ratio is too
high, press a switch in the hard direction to set the mode to [4] or
[5].
If the shoe slip ratio is low and there seems to be lack of power,
press the switch in the soft direction to set the mode to [2] or [1].

6 - 17
.

SHOE SLIP CONTROL ATTACHMENTS, OPTIONS

REMARK
After the joystick is set to F1, the shoe slip control starts when
the ripper lever is operated to LOWER (c) or TILT. Even when
the operation alternates between dozing and ripping, there is no
need to turn the switch ON or OFF.
With this system, if shoe slippage occurs during ripping
operations, the engine speed is lowered to prevent wasteful
shoe slippage.
If shoe slippage occurs during ripping operations and the
engine speed goes down, if the ripper lever is operated to TILT
IN (A) or RAISE (a), the engine speed will rise (output is
increased) to make it easier to carry out breaking operations.
When carrying out ripping operations on hard rock, if the rear of
the machine comes off the ground and there is sudden shoe
slippage, it is possible to reduce the shoe slippage by operating
the ripper to LOWER (c) and reducing the engine speed.

6 - 18
.

ATTACHMENTS, OPTIONS SHOE SLIP CONTROL

REVERSE SLOW MODE

This reduces the travel speed when traveling in reverse, reduces
the frequency of operating the decelerator pedal, and improves the
riding comfort for the operator.
Speed ranges that can be used: R1, 2, 3
(If this mode is only necessary when traveling in R2 or R3, it is
possible to change the setting of the service mode. To do this,
please contact your Komatsu distributor.)
Applicable operations: Traveling on bedrock, traveling down
steep hills

Use this mode to reduce the travel speed when traveling in R1, R2, or R3.
When the reverse slow mode is ON, the travel speed is set to approx. 80% of the full travel speed.
Use this mode to reduce the travel speed when traveling in reverse after ripping and dozing bedrock or when
traveling in reverse after dozing on steep slopes. The travel speed differs in each mode according to whether it is
used in combination with the economy mode or with shoe slip control.
When using shoe slip control, the travel speed for bedrock setting
modes [1] - [5] is set at approx. 70 - 90% of the full travel speed.

When traveling on bedrock, if it is felt that the travel speed when

traveling in reverse is too high, turn the reverse slow mode ON.
This will reduce the travel speed when traveling in reverse.

When traveling down slopes, if it is felt that the travel speed when
traveling in reverse is too high, turn the reverse slow mode ON.
This will reduce the travel speed when traveling in reverse.

6 - 19
.

SHOE SLIP CONTROL ATTACHMENTS, OPTIONS

PROCEDURE FOR SELECTING MODE ACCORDING TO NATURE OR NEEDS TO WORK

Use the table below to select the mode that matches the nature or needs of the operation.

6 - 20
.

ATTACHMENTS, OPTIONS SHOE SLIP CONTROL

IF MODE SELECTION SYSTEM FLASHES

If the caution lamp flashes, or it becomes impossible to control the engine speed with the fuel control dial or
decelerator pedal, stop operation immediately, check the monitor panel display, then contact your Komatsu
distributor for repairs.
In addition to the above problems, if any of the problems in the table below occur, there is probably an abnormality
in the work equipment lever switch, transmission speed range sensor, or other part, so please contact your Komatsu
distributor for repairs.

Mode Operation Abnormality

When shoe slip occurs, it is impossible to throttle power
Even when there is shoe slippage, it is impossible to control
After slippage stops, it takes a long time for power to recover
It becomes difficult to break rock by operating lever to TILT or RAISE
Shoe slip control Ripping
Travel speed increases when shank is inserted
Travel speed is slow and drawbar pull is lacking
No sense of control, engine stays at full or partial
Chassis flies when starting ripping

6 - 21
.

HANDLING MACHINES EQUIPPED WITH KOMTRAX ATTACHMENTS, OPTIONS

HANDLING MACHINES EQUIPPED WITH KOMTRAX

KOMTRAX is a machine management system that uses wireless communications.
A contract with your Komatsu distributor is necessary before the KOMTRAX system can be used. Any customers
desiring to use the KOMTRAX system should consult their Komatsu distributor.
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. Always
contact your Komatsu distributor before selling or exporting any machine equipped with KOMTRAX.
When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary,
it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to
stop communications.
If you do not obey the above precautions, neither Komatsu nor your Komatsu distributor can take any
responsibility for any problem that is caused or for any loss that results.

BASIC PRECAUTIONS
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 distributor will carry out removal and installation of
KOMTRAX.)
Do not allow cables or cords to become caught; do not damage or pull cables or cords by force. Short circuits or disconnected
wires may cause failure or fire on the KOMTRAX equipment or the machine itself.
For anyone wearing a pacemaker, make sure that the communications antenna is at least 22 cm (8.7 in) from the pacemaker.
The radio waves may have an adverse effect on the operation of the pacemaker.

NOTICE
Even when the key in the starting switch of the KOMTRAX system is at the OFF position, a small amount of electric power is
consumed. When putting the machine into long-term storage, take the action given in "LONG-TERM STORAGE (PAGE 3-152)".
Please contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof.
Be careful not to get water on the communications terminal or wiring.

REMARK
The KOMTRAX system 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.
There is absolutely no need to inspect or operate the KOMTRAX communications terminal, but if any abnormality
is found, please consult your Komatsu distributor.

6 - 22
.

INDEX

INDEX

<A>
ADJUSTING POSTURE OF WORK <F>
EQUIPMENT 3-137 FRONT PANEL 3- 5
AIR CONDITIONER, HANDLING 3- 68 FRONT/REAR, LEFT/RIGHT
ASHTRAY 3- 58 DIRECTIONS OF MACHINE 1- 4
FUSE BOX 3- 51
<B>
BEFORE READING THIS MANUAL 1- 2 <G>
BLADE SERIAL NO. PLATE POSITION 1- 7 GENERAL PRECAUTIONS 6- 2
PRECAUTIONS RELATED TO
<C> SAFETY 6- 2
CAP WITH LOCK 3- 55 GENERAL PRECAUTIONS COMMON
CAR STEREO, HANDLING 3- 60 TO OPERATION AND MAINTENANCE 2- 10
CHECK AFTER FINISHING WORK 3-121 DO NOT GET CAUGHT IN WORK
CHECK AFTER STOPPING ENGINE 3-120 EQUIPMENT 2- 15
CHECK BEFORE STARTING ENGINE, FIRE PREVENTION 2- 12
ADJUST 3- 73 PRECAUTIONS BEFORE STARTING
COLD WEATHER OPERATION 3-149 OPERATION 2- 10
AFTER COLD WEATHER 3-151 PRECAUTIONS RELATED TO
AFTER COMPLETION OF WORK 3-151 ATTACHMENTS AND OPTIONS 2- 15
PRECAUTIONS FOR LOW PRECAUTIONS RELATED TO
TEMPERATURE 3-149 PROTECTIVE STRUCTURES 2- 15
CONTROL LEVERS, PEDALS 3- 40 PRECAUTIONS WHEN GETTING ON
OR OFF MACHINE 2- 13
<D> PRECAUTIONS WHEN RUNNING
DOOR OPEN LOCK 3- 57 ENGINE INSIDE BUILDING 2- 16
DOOR POCKET 3- 58 PREPARATIONS FOR SAFE
DUST INDICATOR 3- 50 OPERATION 2- 10
UNAUTHORIZED MODIFICATION 2- 15
<E> GENERAL VIEW 3- 2
EFFECTIVE METHOD OF OPERATION GENERAL VIEW OF CONTROLS AND
FOR DUAL TILTDOZER 6- 5 GAUGES 3- 3
BLADE CONDITION 6- 5 GENERAL VIEW OF MACHINE 3- 2
BOULDER RAISING OPERATION 6- 10 GUIDES TO MAINTENANCE 4- 2
DITCHING OPERATION 6- 10
DOZING WORK 6- 7 <H>
HORIZONTAL DOZING HANDLING HYDRAULIC RELATED
OPERATIONS FROM SIDE SLOPE EQUIPMENT 4- 10
(ROUGH GROUND) 6- 11 HANDLING MACHINES EQUIPPED
LEVELING (SPREADING) WITH KOMTRAX 6- 22
OPERATION 6- 10 BASIC PRECAUTIONS 6- 22
SIDE-CUTTING OPERATIONS 6- 11 HANDLING OIL, FUEL, COOLANT, AND
EFFECTIVE USE OF MODE PERFORMING OIL CLINIC 4- 5
SELECTION SYSTEM 3-124
EPA REGULATIONS, ENGINE NUMBER <I>
PLATE 1- 6 INSTALLATION OF CAB 3-148
EXPLANATION OF COMPONENTS 3- 5 INTRODUCTION 1- 4

7-1
.

INDEX

<L> <R>
LOADING, UNLOADING WORK 3-143 RECOMMENDED FUEL, COOLANT,
LOCKING 3-121 AND LUBRICANT 4- 13
LONG-TERM STORAGE 3-152 REMOVAL OF CAB 3-148
AFTER STORAGE 3-152 RIPPER OPERATION 3-129
BEFORE STORAGE 3-152 RIPPER SERIAL NO. PLATE POSITION 1- 7
DURING STORAGE 3-152
STARTING MACHINE AFTER <S>
LONG-TERM STORAGE 3-152 SAFETY 2- 2
SAFETY CRITICAL PARTS 4- 17
<M> SAFETY INFORMATION 1- 3
MAINTENANCE SCHEDULE CHART 4- 19 SAFETY LABELS 2- 5
METHOD OF LIFTING MACHINE 3-146 SASH GLASS INTERMEDIATE LOCK 3- 58
MOVING MACHINE 3-104 SELECTION OF TRACK SHOE 6- 3
SELECTION OF TRACK SHOES 6- 3
<N> SERVICE PROCEDURE 4- 21
NECESSARY INFORMATION 1- 6 CHECK BEFORE STARTING 4- 50
EVERY 1000 HOURS SERVICE 4- 64
<O> EVERY 2000 HOURS SERVICE 4- 72
OPERATING METHOD FOR RIPPING EVERY 250 HOURS SERVICE 4- 51
OPERATIONS 3-132 EVERY 4000 HOURS SERVICE 4- 82
OPERATION 3- 73 EVERY 500 HOURS SERVICE 4- 58
OPERATIONS AND CHECKS AFTER EVERY 8000 HOURS SERVICE 4- 86
STARTING ENGINE 3-100 INITIAL 250 HOURS SERVICE (ONLY
OUTLINE OF ELECTRIC SYSTEM 4- 9 AFTER THE FIRST 250 HOURS) 4- 21
OUTLINES OF SERVICE 4- 5 WHEN REQUIRED 4- 22
SHIFTING BETWEEN FORWARD AND
<P> REVERSE 3-112
PARKING MACHINE 3-119 SHIFTING GEAR 3-107
PERIODIC REPLACEMENT OF SAFETY SHOE SLIP CONTROL 6- 12
CRITICAL PARTS 4- 17 EFFECTIVE USE OF MODE
POSITION OF SERVICE METER 1- 7 SELECTION SYSTEM 6- 14
POWER SOURCE 3- 50 IF MODE SELECTION SYSTEM
PRECAUTIONS FOR MAINTENANCE 2- 28 FLASHES 6- 21
PRECAUTIONS BEFORE STARTING MODE SELECTION SWITCH PANEL
INSPECTION AND MAINTENANCE 2- 28 (SHOE SLIP CONTROL) 6- 12
PRECAUTIONS FOR INSPECTION SPECIFICATIONS 5- 2
AND MAINTENANCE 2- 32 STANDARD TIGHTENING TORQUES
PRECAUTIONS FOR OPERATION 2- 17 FOR BOLTS AND NUTS 4- 16
OPERATION 2- 22 STARTING ENGINE 3- 95
PRECAUTIONS FOR JOBSITE 2- 17 STEERING MACHINE 3-114
STARTING ENGINE 2- 19 STOPPING ENGINE 3-103
TOWING 2- 27 STOPPING MACHINE 3-106
TRANSPORTATION 2- 26 SWITCHES 3- 36
PRECAUTIONS FOR OPERATION 3-117
PROCEDURE FOR SELECTING <T>
RIPPER POINT 6- 4 TABLE TO ENTER SERIAL NO. AND
PRODUCT IDENTIFICATION NUMBER DISTRIBUTOR 1- 8
(PIN), MACHINE SERIAL NO. PLATE 1- 6

7-2
.

INDEX

TIPS FOR LONGER UNDERCARRIAGE

LIFE 3-141
TOOL BOX 3- 59
TORQUE LIST 4- 16
TRANSPORTATION 3-143
TRANSPORTATION PROCEDURE 3-143
TRAVELING ON ROADS 3-147
TROUBLESHOOTING 3-153
AFTER RUNNING OUT OF FUEL 3-153
IF BATTERY IS DISCHARGED 3-155
METHOD OF TOWING MACHINE 3-154
OTHER TROUBLE 3-159
WHEN MODE SELECTION SYSTEM
FLASHES 3-164

<U>
USE OF MACHINE 1- 4

<V>
VISIBILITY FROM OPERATOR'S SEAT 1- 5

<W>
WEAR PARTS 4- 11
WEAR PARTS LIST 4- 11
WORK POSSIBLE USING BULLDOZER 3-122

7-3
.

D275AX-5E0 BULLDOZER
Form No. TEN00352-00

©
2009 KOMATSU
All Rights Reserved
Printed in Japan 04-09