Omm D85ess-5833 and Up

PEN01634-03
BULLDOZER D85ESS -2A

SERIAL NUMBERS D85ESS-5833 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.
FOREWORD
11
1-1
FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precau-
tions in this manual must be followed at all times when performing operation and maintenance. Most accidents are
caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents
can be prevented by knowing beforehand conditions that may cause hazard when performing operation and main-
tenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.
● Always be sure to read and understand this manual thoroughly before performing operation and
maintenance.
● Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and
have all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual
immediately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operat-
ing the machine.
Storage location for the Operation and Maintenance Manual:
Machine equipped with cab
Inside of right and left doors
Machine without cab
Back pocket of operator's seat
1-2
FOREWORD SAFETY INFORMATION
Some of Komatsu machines have the software based on the Open Source Software (OSS).
By the license of the OSS, Komatsu publishes the license information of the software to be used in the website
that follows.
https://www.komatsu.jp/en/ProductInfo/opensoft/
1-2-1
SAFETY INFORMATION FOREWORD
1-2-2
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
DANGER ous injury. This signal word is to be limited to most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
WARNING serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
CAUTION erate injury. It may also be used to alert against unsafe practices.
Example of safety message using signal word
WARNING
To avoid hitting unlocked operation levers, lower equipment to ground and move WORK EQUIPMENT
LOCK LEVER (located near seat) to LOCK position before starting up from operator's seat.
Sudden and unwanted machine movement can cause serious injury or death.
Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is are useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
NOTICE the life of the machine.
This gives information that is useful to know.

REMARKS
1-3
SAFETY INFORMATION FOREWORD
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Part No.
Safety labels using pictogram

Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side, and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Part No.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your
responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: → (1))
1-4
FOREWORD INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following works:
● Dozing
● Smoothing
● Cutting into hard or frozen ground or ditching.
● Felling trees, removing stumps
See the section "WORK POSSIBLE USING BULLDOZER (PAGE 3-92)" for further details.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's cab when
the operator's cab is facing the front and the sprocket is at the rear of the machine.
1-5
NECESSARY INFORMATION FOREWORD
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NO. PLATE AND POSITION

This is at the front bottom right of the operator's seat.
ENGINE SERIAL NO. PLATE AND POSITION

This is at the center of the side face of the engine cylinder block on the left side of the machine.
1-6
FOREWORD NECESSARY INFORMATION
POSITION OF SERVICE METER

Monitor panel specification
This is at the left upper part of the monitor panel.
Gauge panel specification

The gauge is located on the left lower part of the monitor panel.
G0163802
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personal
Phone/Fax
1-7
CONTENTS FOREWORD
CONTENTS
FOREWORD
FOREWORD......................................................................................................................................................... 1-2
SAFETY INFORMATION...................................................................................................................................... 1-3
INTRODUCTION................................................................................................................................................... 1-5
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE ....................................................................... 1-5
NECESSARY INFORMATION ............................................................................................................................. 1-6

MACHINE SERIAL NO. PLATE AND POSITION ....................................................................................... 1-6
ENGINE SERIAL NO. PLATE AND POSITION .......................................................................................... 1-6
POSITION OF SERVICE METER .............................................................................................................. 1-7
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR .............................................................................. 1-7
SAFETY
SAFETY ................................................................................................................................................................ 2-2
SAFETY LABELS................................................................................................................................................. 2-4

POSITIONS OF SAFETY PICTOGRAMS .................................................................................................. 2-4
SAFETY LABELS ....................................................................................................................................... 2-5
GENERAL PRECAUTIONS ................................................................................................................................. 2-8
PRECAUTIONS FOR OPERATION ................................................................................................................... 2-17

STARTING ENGINE ................................................................................................................................. 2-17
OPERATION............................................................................................................................................. 2-19
TRANSPORTATION................................................................................................................................. 2-23
BATTERY ................................................................................................................................................. 2-24
TOWING ................................................................................................................................................... 2-26
PRECAUTIONS FOR MAINTENENCE .............................................................................................................. 2-27
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE ................................................................................................................. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-6

MONITOR PANEL ...................................................................................................................................... 3-6
GAUGE PANEL ........................................................................................................................................ 3-10
SWITCHES ............................................................................................................................................... 3-12
LAMP ........................................................................................................................................................ 3-17
1-8
FOREWORD CONTENTS
CONTROL LEVERS AND PEDALS ......................................................................................................... 3-18

FUSE ........................................................................................................................................................ 3-24
ELECTRIC POWER TAKE-OUT ADAPTER ............................................................................................ 3-26
DOOR-OPEN LOCK ................................................................................................................................. 3-27
SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-27
CAP, COVER WITH LOCK....................................................................................................................... 3-28
HOT AND COOL BOX .............................................................................................................................. 3-29
OPERATION MANUAL STORAGE .......................................................................................................... 3-29
ASHTRAY ................................................................................................................................................. 3-30
TOOL BOX................................................................................................................................................ 3-30
GREASE PUMP HOLDER........................................................................................................................ 3-30
CAR STEREO........................................................................................................................................... 3-31
AIR CONDITIONER.................................................................................................................................. 3-39
HEATER ................................................................................................................................................... 3-45
OPERATION....................................................................................................................................................... 3-48
CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-48
STARTING ENGINE ................................................................................................................................. 3-66
OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................................................... 3-73
STOPPING ENGINE................................................................................................................................. 3-76
CHECK AFTER STOPPING ENGINE ...................................................................................................... 3-78
MACHINE OPERATION ........................................................................................................................... 3-79
SHIFTING GAER ...................................................................................................................................... 3-83
SHIFTING BETWEEN FORWARD AND REVERSE ................................................................................ 3-84
STEERING MACHINE .............................................................................................................................. 3-86
PRECAUTIONS FOR OPERATION ......................................................................................................... 3-90
WORK POSSIBLE USING BULLDOZER ................................................................................................. 3-92
ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................... 3-94
PARKING MACHINE .............................................................................................................................. 3-102
CHECK AFTER FINISHING WORK ....................................................................................................... 3-103
LOCKING................................................................................................................................................ 3-104
TIPS FOR LONGER UNDERCARRIAGE LIFE ...................................................................................... 3-105
TRANSPORTATION......................................................................................................................................... 3-109
TRANSPORTATION MEANS ................................................................................................................. 3-109
REMOVING CAB .................................................................................................................................... 3-109
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................... 3-109
LOADING, UNLOADING WORK ............................................................................................................ 3-111
LIFTING MACHINE................................................................................................................................. 3-115
COLD WEATHER OPERATION ...................................................................................................................... 3-117

PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................ 3-117
AFTER COMPLETION OF WORK ......................................................................................................... 3-119
AFTER COLD WEATHER ...................................................................................................................... 3-119
LONG-TERM STORAGE.................................................................................................................................. 3-120

BEFORE STORAGE............................................................................................................................... 3-120
DURING STORAGE ............................................................................................................................... 3-120
AFTER STORAGE.................................................................................................................................. 3-120
1-9
CONTENTS FOREWORD
TROUBLESHOOTING...................................................................................................................................... 3-121
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-121
TOWING THE MACHINE ....................................................................................................................... 3-121
IF BATTERY IS DISCHARGED.............................................................................................................. 3-122
OTHER TROUBLE ................................................................................................................................. 3-126
MAINTENANCE
GUIDE TO MAINTENANCE ................................................................................................................................. 4-2
OUTLINE OF SERVICE........................................................................................................................................ 4-5

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...................................................... 4-5
BATTERY TERMINAL.................................................................................................................................. 4-8
RELATING TO ELECTRIC SYSTEM ......................................................................................................... 4-9
WEAR PARTS .................................................................................................................................................... 4-10

WEAR PARTS LIST.................................................................................................................................. 4-10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................................................................................. 4-11

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............. 4-12
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
GENUINE OIL........................................................................................................................................... 4-13
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-14

TORQUE LIST .......................................................................................................................................... 4-14
DEFINED LIFE PARTS ........................................................................................................................................ 4-15

DEFINED LIFE PARTS............................................................................................................................... 4-16
MAINTENANCE SCHEDURE CHART ............................................................................................................... 4-17

MAINTENANCE SCHEDURE CHART ..................................................................................................... 4-17
SERVICE PROCEDURE .................................................................................................................................... 4-19

WHEN REQUIRED ................................................................................................................................... 4-19
CHECK BEFORE STARTING .................................................................................................................. 4-45
EVERY 50 HOURS SERVICE .................................................................................................................. 4-46
EVERY 250 HOURS SERVICE ................................................................................................................ 4-47
EVERY 500 HOURS SERVICE ................................................................................................................ 4-57
EVERY 1000 HOURS SERVICE .............................................................................................................. 4-60
SPECIFICATIONS
SPECIFICATIONS ................................................................................................................................................ 5-2
1-10
FOREWORD CONTENTS
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS ................................................................................................................................. 6-2
PRECAUTIONS RELATED TO SAFETY ................................................................................................... 6-2
SUSPENSION SEAT ............................................................................................................................................ 6-3
HEADREST .......................................................................................................................................................... 6-4
HANDLING ACCUMULATOR.............................................................................................................................. 6-5
EQUIPPING THE FIRE EXTINGUISHER AND THE FIRST-AID KIT .................................................................. 6-7
HANDLING TOWING WINCH .............................................................................................................................. 6-8

EXPLANATION OF CONTROLS................................................................................................................ 6-8
OPERATION............................................................................................................................................... 6-9
MAINTENANCE........................................................................................................................................ 6-11
SPECIFICATIONS .................................................................................................................................... 6-12
INDEX ................................................................................................................................................................... 7-1
1-11
CONTENTS FOREWORD
MEMO
1-12
SAFETY
21
WARNING
Please read and make sure that you fully understand the
precautions described in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precautions strictly.
2-1
SAFETY SAFETY
SAFETY
SAFETY LABELS.................................................................................................................................................. 2-4
POSITIONS OF SAFETY PICTOGRAMS ....................................................................................................... 2-4
SAFETY LABELS............................................................................................................................................. 2-5
GENERAL PRECAUTIONS .................................................................................................................................. 2-8

SAFETY RULES ......................................................................................................................................... 2-8
IF ABNORMALITIES ARE FOUND ............................................................................................................ 2-8
CLOTHING AND PERSONAL PROTECTIVE ITEMS ................................................................................ 2-8
FIRE EXTINGUISHER AND FIRST AID KIT .............................................................................................. 2-8
SAFETY FEATURES .................................................................................................................................. 2-9
KEEP MACHINE CLEAN............................................................................................................................ 2-9
INSIDE OPERATOR'S COMPARTMENT................................................................................................... 2-9
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT .............................................................. 2-9
HANDRAILS AND STEPS ........................................................................................................................ 2-10
MOUNTING AND DISMOUNTING ........................................................................................................... 2-11
NO PEOPLE ON ATTACHMENTS ........................................................................................................... 2-11
CRUSHING OR CUTTING PREVENTION ............................................................................................... 2-11
PREVENTION OF BURNS ....................................................................................................................... 2-12
FIRE PREVENTION ................................................................................................................................. 2-12
ACTION IF FIRE OCCURS ...................................................................................................................... 2-13
WINDOW WASHER LIQUID .................................................................................................................... 2-13
PRECAUTIONS WHEN USING ROPS .................................................................................................... 2-13
PRECAUTIONS FOR ATTACHMENTS ................................................................................................... 2-14
UNAUTHORIZED MODIFICATION .......................................................................................................... 2-14
SAFETY AT WORKSITE .......................................................................................................................... 2-14
WORKING ON LOOSE GROUND............................................................................................................ 2-15
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES ............................................................................... 2-15
ENSURE GOOD VISIBILITY .................................................................................................................... 2-15
VENTILATION FOR ENCLOSED AREAS ................................................................................................ 2-16
CHECKING SIGNALMAN'S SIGNALS AND SIGNS ................................................................................ 2-16
EMERGENCY EXIT FROM OPERATOR’S CAB ..................................................................................... 2-16
BE CAREFUL ABOUT ASBESTOS DUST ............................................................................................... 2-16
2-2
SAFETY SAFETY
PRECAUTIONS FOR OPERATION ................................................................................................................... 2-17

STARTING ENGINE ...................................................................................................................................... 2-17
CHECKS BEFORE STARTING ENGINE ................................................................................................. 2-17
PRECAUTIONS WHEN STARTING......................................................................................................... 2-18
PRECAUTIONS IN COLD AREAS ........................................................................................................... 2-18
OPERATION.................................................................................................................................................. 2-19
CHECKS BEFORE OPERATION ............................................................................................................. 2-19
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE ............................................. 2-19
PRECAUTIONS WHEN TRAVELING....................................................................................................... 2-20
TRAVELING ON SLOPES........................................................................................................................ 2-21
USING BRAKES ....................................................................................................................................... 2-21
OPERATE CAREFULLY ON SNOW ........................................................................................................ 2-21
PARKING MACHINE ................................................................................................................................ 2-22
TRANSPORTATION...................................................................................................................................... 2-23
LOADING AND UNLOADING................................................................................................................... 2-23
SHIPPING................................................................................................................................................. 2-23
BATTERY ...................................................................................................................................................... 2-24
BATTERY HAZARD PREVENTION ......................................................................................................... 2-24
STARTING WITH BOOSTER CABLE ...................................................................................................... 2-25
TOWING ........................................................................................................................................................ 2-26
WHEN TOWING ....................................................................................................................................... 2-26
PRECAUTIONS FOR MAINTENENCE .............................................................................................................. 2-27

WARNING TAG ........................................................................................................................................ 2-27
KEEP WORK PLACE CLEAN AND TIDY................................................................................................. 2-27
APPOINT LEADER WHEN WORKING WITH OTHERS .......................................................................... 2-27
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE .................................. 2-28
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ................................................. 2-29
PROPER TOOLS...................................................................................................................................... 2-29
NO UNAUTHORIZED PERSONNEL INTO AREA ................................................................................... 2-29
ATTACHMENTS ....................................................................................................................................... 2-30
PRECAUTIONS FOR WORK UNDER MACHINE AND WORK EQUIPMENT......................................... 2-30
NOISE....................................................................................................................................................... 2-30
PRECAUTIONS WHEN USING HAMMER............................................................................................... 2-30
REPAIR WELDING................................................................................................................................... 2-31
REMOVING BATTERY TERMINAL.......................................................................................................... 2-31
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION ............. 2-31
DO NOT DISASSEMBLE RECOIL SPRING ............................................................................................ 2-31
PRECAUTION WITH HIGH-PRESSURE OIL .......................................................................................... 2-32
HANDLING HIGH-PRESSURE HOSES................................................................................................... 2-32
WASTE MATERIAL .................................................................................................................................. 2-32
MAINTENANCE FOR AIR CONDITIONER .............................................................................................. 2-33
COMPRESSED AIR ................................................................................................................................. 2-33
PERIODIC INSPECTION OF DEFINED LIFE PARTS .............................................................................. 2-33
2-3
SAFETY LABELS SAFETY
SAFETY LABELS
The following warning signes 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, there may cause the labels to
peel off.
● There are also other labels in addition to the warning signes 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
2-4
SAFETY SAFETY LABELS
SAFETY LABELS
(1) Precautions for operation, inspection and mainte- (2) Precautions when traveling in reverse
nance (09651-A0641) (09802-B0750)
(3) Precautions for leaving the operator's seat (4) Precautions for high-temperature hydraulic oil
(09654-B0641) (09653-A0481)
2-5
SAFETY LABELS SAFETY
(5) Precautions for handling accumulator (6) Precautions for check and adjust track tension
(09659-A057B) (09657-A0881)
Safety label is attached on the back side of the

inspection cover of the track frame.
(7) Precautions for handling electric wires (8) Caution for engine running (09667-A0481)
(09808-A0881)
2-6
SAFETY SAFETY LABELS
(9) Caution for approach when machine moving (10) Warning for ROPS
(09806-B1201) (09620-30200)
(11) Caution for blast site (09845-00480)

(only when equipped with KOMTRAX)
2-7
GENERAL PRECAUTIONS SAFETY
GENERAL PRECAUTIONS
SAFETY RULES
● Only trained and authorized personnel can operate and maintain the machine.
● Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
● If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine
may be severly impaired putting yourself and everyone else on your jobsite in danger.
● When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-
stand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND

If you find any abnormality 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 abnormality has been cor-
rected.
CLOTHING AND PERSONAL PROTECTIVE ITEMS

● Do not wear loose clothing and accessories. There is a
hazard that they may catch on control levers or other pro-
truding parts.
● If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
● Always wear a hard hat and safety shoes. If the nature of

the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
● Check that all protective equipment functions properly before using it.
FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur.
● Be sure that fire extinguishers have been provided and

read the labels to ensure that you know how to use them in
emergencies.
● Carry out periodic inspection and maintenance to ensure

that the fire extinguisher can always be used.
● Provide a first aid kit at the storage point. Carry out periodic
checks and add to the contents if necessary.
2-8
SAFETY GENERAL PRECAUTIONS
SAFETY FEATURES
● Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately
if they are damaged.
● Understand the method of use of safety features and use them properly.
● Never remove any safety features. Always keep them in good operating condition.
KEEP MACHINE CLEAN

● If water gets into the electrical system, there is a hazard
that it will cause malfunctions or misoperation. Do not use
water or steam to wash the electrical system (sensors,
connectors).
● If inspection and maintenance is carried out when the

machine is still dirty with mud or oil, there is a hazard that
you will slip and fall, or that dirt or mud will get into your
eyes. Always keep the machine clean.
INSIDE OPERATOR'S COMPARTMENT

● When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you
operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious acci-
dent.
● Do not leave parts or tools lying around the operator's compartment.
● Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
● Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
● Never bring any dangerous objects such as flammable or explosive items into the operator's cab.
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT

● Before standing up from the operator's seat (such as when
adjusting the operator's seat), lower the work equipment
completely to the ground, set work equipment lock lever (1)
and brake lock lever (2) securely to the LOCK position,
then stop the engine.
If you accidentally touch the levers when they are not
locked, there is a hazard that the machine may suddenly
move and cause serious injury or property damage.
2-9
● When leaving the machine, always lower the work equip-

ment completely to the ground, set work equipment lock
lever (1) and brake lock lever (2) securely to the LOCK
position, then stop the engine. Use the key to lock all the
equipment. Always remove the key, take it with you, and
keep it in the specified place.
HANDRAILS AND STEPS

To prevent personal injury caused by slipping or falling off the machine, always do as follows.
● Use the handrails and steps marked by arrows in the dia-

gram on the right when getting on or off the machine.
● To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands
and one foot) with the handrails and steps (including the
track shoe) to ensure that you support yourself.
● Do not grip the control levers when getting on or off the

machine.
● Never climb on the engine hood or covers where there are

no non-slip pads.
● Before getting on or off the machine, check the handrails and steps (including the track shoe). If there is any
oil, grease, or mud on the handrails or steps (including the track shoe), wipe it off immediately. Always keep
these parts clean. Repair any damage and tighten any loose bolts.
● Do not get on or off the machine while holding tools in your hand.
2-10
MOUNTING AND DISMOUNTING

● Never jump on or off the machine. Never get on or off a moving machine.
● If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try
to stop it.
NO PEOPLE ON ATTACHMENTS
Never let anyone ride on the attachments. There is a hazard of falling and suffering serious injury.
CRUSHING OR CUTTING PREVENTION

Do not put your hand, arm or any other part of your body between movable parts such as the work equipment and
cylinders, or between the machine and work equipment.When the work equipment is operated, the clearance will
change and this may lead to serious damage or personal injury.
2-11
PREVENTION OF BURNS
Hot coolant
● To prevent burns from hot water or steam spurting out
when checking or draining the coolant, wait for the water to
cool to a temperature where it is possible to touch the radi-
ator cap by hand before starting the operation. Even when
the coolant has cooled down, loosen the cap slowly to
relieve the pressure inside the radiator before removing the
cap.
Hot oil
● To prevent burns from hot oil or other parts when checking
or draining the oil, wait for the oil to cool to a temperature
where it is possible to touch the cap by hand before start-
ing the operation. Even when the oil has cooled down,
loosen the plug slowly to relieve the internal pressure
before removing the plug.
FIRE PREVENTION
● Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particu-
larly flammable and can be hazardous. To prevent fire,
always observe the following:
● Do not smoke or use any flame near fuel or oil.
● Stop the engine before refueling.
● Do not leave the machine while adding fuel or oil.
● Tighten all fuel and oil caps securely.
● Do not spill fuel on overheated surfaces or on parts of

the electrical system.
● Use well-ventilated areas for adding or storing oil and

fuel.
● Keep oil and fuel in the determined place and do not

allow unauthorized persons to enter.
● After adding fuel or oil, wipe up any spilled fuel or oil.
● When carrying out grinding or welding work on the

chassis, move any flammable materials to a safe place
before starting.
● When washing parts with oil, use a non-flammable oil. Diesel oil and gasoline may catch fire, so do not
use them.
● Put greasy rags and other flammable materials into a safe container to maintain safety at the work place.
2-12
● Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
● Fire caused by accumulation of flammable material.

● Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or
affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
● Fire coming from electric wiring

Short circuits in the electrical system can cause fire.
● Always keep electric wiring connections clean and securely tightened.
● Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
● Fire coming from hydraulic line

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose,
they may vibrate during operation and rub against other parts. This may lead to damage to the hoses, and
cause high-pressure oil to spurt out, leading to fire damage or serious injury.
● Explosion caused by lighting equipment

● When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, use explosion-proof lighting.
If you do not use explosion-proof lighting, there is a hazard of serious injury or damage caused by explo-
sion.
● When taking the electrical power for the lighting from the machine, follow the instructions in this manual.
ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows.
● Turn the starting switch OFF and stop the engine.
● Use the handrails and steps to get off the machine.
WINDOW WASHER LIQUID

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

Install ROPS when working in places where there is danger of
falling rocks, such as in mines and quarries, or in places where
there is danger of rolling over.
● If ROPS is installed, do not remove it when operating the

machine.
● ROPS is installed to protect the operator when machine

rolls over. When machine rolls over, ROPS supports its
weight and absorbs its impact energy.
● If ROPS is modified, its strength may lower. When modify-

ing it, consult your Komatsu distributor.
● If ROPS is deformed by falling objects or by rolling over, its strength lowers and its design functions cannot be
maintained. In this case, be sure to ask your Komatsu distributor about repair method.
2-13
● Even if ROPS is installed, it does not work normally, if your seat belt is not fastened. Be sure to fasten your
seat belt when operating machine.
PRECAUTIONS FOR ATTACHMENTS

● When installing optional parts or attachments, there may be problems with safety or legal restrictions, so
please contact your Komatsu distributor for advice.
● Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
● When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.
UNAUTHORIZED MODIFICATION
Any modification mode without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
● Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications
made without authorization from Komatsu.
SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
● When carrying out operations near combustable materials such as thatched roofs, dry leaves or dry grass,
there is a hazard of fire, so be careful when operating.
● Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not carry out operations at places where there is a hazard of landslides or falling rocks.
● If water lines, gas lines, or high-voltage electrical lines may

be buried under the worksite, contact each utility and iden-
tify 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 shallow water or on soft ground, check the shape and condition of the bedrock,
and the depth and speed of flow of the water before starting operations.
2-14
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.
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause
serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as
follows.
● Before starting work near electric cables, inform the local power company of the work to be performed, and
ask them to take the necessary action.
● Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death.
Min. safety
Always maintain a safe distance (see the table on the right) Voltage
distance
between the machine and the electric cable. Check with
the local power company about safe operating procedure 100V 200V 2m
before starting operations. Low
voltage 6,600V 2m
● To prepare for any possible emergencies, wear rubber
shoes and gloves. Lay a rubber sheet on top of the seat, 22,000V 3m
and be careful not to touch the chassis with any exposed
66,000V 4m
part of your body.
Very high 154,000V 5m
● Use a signalman to give warning if the machine
approaches too close to the electric cables. voltage 187,000V 6m
● When carrying out operations near high voltage cables, do 275,000V 7m

not let anyone come close to the machine.
500,000V 11m
● 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 con-
firmed that the electricity has been shut off. Also, do not let
anyone come close to the machine.
ENSURE GOOD VISIBILITY

Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to
ensure that operations and travel can be carried out safely. Always do as follows.
● Position a signalman if there are areas at the rear of the machine where the visibility is not good.
● When working in dark places, turn on the working lamp and front lamps installed to the machine, and set
up additional lighting in the work area if necessary.
● Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
2-15
VENTILATION FOR ENCLOSED AREAS

Exhaust fumes from the engine can kill.
● If it is necessary to start the engine within an enclosed

area, or when handling fuel, flushing oil, or paint, open the
doors and windows to ensure that you provide adequate
ventilation is provided to prevent gas poisoning.
CHECKING SIGNALMAN'S SIGNALS AND SIGNS

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

Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsites
handling demolition work or work handling industrial waste.
Always observe the following.
● Spray water to keep down the dust when cleaning. Do not

use compressed air for cleaning.
● If there is danger that there may be asbestos dust in the

air, always operate the machine from an upwind position.
All workers should use an approved respirator.
● Do not allow other persons to approach during the operation.
● Always observe the rules and regulations for the work site and environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always
use genuine Komatsu parts.
2-16
SAFETY PRECAUTIONS FOR OPERATION
PRECAUTIONS FOR OPERATION
STARTING ENGINE
If there is a warning tag hanging from the work equipment con-
trol lever, do not start the engine or touch the levers.
CHECKS BEFORE STARTING ENGINE

Carry out the following checks before starting the engine at the beginning of the day's work.
● Remove all dirt from the surface of the window glass to ensure a good view.
● 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 the battery terminals for looseness or corrosion.
● Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no dam-
age or wear to the seat belt or mounting clamps.
● Check that the gauges work properly, check the angle of the lights and working lamps, and check that the con-
trol levers are all at the neutral position.
● Check that there are no persons or obstacles above, below, or in the area around the machine.
2-17
PRECAUTIONS FOR OPERATION SAFETY
PRECAUTIONS WHEN STARTING

● When starting the engine, sound the horn as a warning.
● Start and operate the machine only while seated.
● Do not allow anyone apart from the operator to ride on the machine.
● Do not short circuit the starting motor circuit to start the engine. It is not only dangerous, but will also cause
damage to the equipment.
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.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check for
frost and leakage of battery electrolyte before starting.
2-18
OPERATION
CHECKS BEFORE OPERATION

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
● Always fasten your seat belt.
● Check the operation of travel, steering and brake systems,

and work equipment control system.
● Check for any abnormality in the sound of the machine,

vibration, heat, smell, or gauges; check also that there is
no leakage of oil or fuel.
● If any abnormality is found, carry out repairs immediately.
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE

● Before travelling, check again that there is no one in the
surrounding area, and that there are no obstacles.
● Before travelling, sound the horn to warn people in the

area.
● Always operate the machine only when seated.
● Do not allow anyone apart from the operator to ride on the

machine.
● Check that the back-up alarm (alarm buzzer when machine

travels in reverse) works properly.
● Fix the operator's compartment doors and windows in position securely.
● If there is an area to the rear of the machine which cannot be seen, position a signal person. Take special care
not to hit other machines or people when turning or swinging the machine.
Always be sure to carry out the above precautions even when the machine is equipped with mirrors.
2-19
PRECAUTIONS WHEN TRAVELING

● When operating the machine, take care that it will not exceed its performance values such as stability, maxi-
mum using load, etc. to prevent rolling of the machine caused by an overload and disasters caused by break-
age of the work equipment.
● When traveling on flat ground, keep its height at 40 to 50 cm (16 to 20 in) above the ground.
● 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 bal-
ance, or may damage the machine or structures in the
area.
● 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.
Never travel over obstacles which make the machine tilt
strongly to one side.
● 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 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 work equipment hit anything.
● Do not approach the edge of a cliff carelessly. When dropping soil over a cliff for banking or reclamation, leave
soil of one scoop at the edge of the cliff and push it with the next scoop.
● When the machine passes over the top of a hill or when a load is dumped over a cliff, the load is suddenly
reduced, and there is danger that the travel speed rises suddenly. To prevent this, lower the travel speed.
● If the machine moves with only either side of the blade loaded, its tail may swing. Take care.
2-20
TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always do as follows.
● When traveling on slopes, keep the work equipment

approximately 20 to 30 cm (8 to 12 in) above the ground. In
case of emergency, quickly 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.
USING BRAKES
● When the machine is traveling, do not rest your foot on the brake pedal. If you travel with your foot resting on
the pedal, the brake will always be applied, and this will cause the brakes to overheat and fail.
● Do not depress the brake pedal repeatedly if not necessary. If this is neglected, the brake will be overheated
and will not work when required.
● When traveling downhill, use the braking force of the engine. If necessary, use the brake pedal at the same
time.
OPERATE CAREFULLY ON SNOW

● Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the
machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.
● With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
● If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful 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 opera-
tions carefully.
● When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and use the
engine as a brake while appling the foot brake intermittently (depress the brake intermittently several times). If
necessary, lower the blade to the ground to stop the machine.
2-21
PARKING MACHINE
● Park the machine on firm, level ground.
● Select a place where there is no hazard of falling rocks or

landslides, or of flooding if the land is low.
● Lower the work equipment completely to the ground.
● When leaving the machine, set the steering, directional

and gear shift levers in the N (Neutral) position and set the
blade lever in the holding position, then apply work equip-
ment lock lever (1) and brake lock lever (2) 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.
● If it is necessary to park the machine on a slope, always do

as follows.
● Set the blade on the downhill side, then dig it into the
ground.
● Put blocks under the tracks to prevent the machine

from moving.
2-22
TRANSPORTATION
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 day, in particular, take extremely careful since the ramp surface is slippery.
● Run the engine at low speed, set to 1st, and operate the machine slowly.
● 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 loading the machine. If this is not done, the door
may suddenly open during transportation.
Refer to "TRANSPORTATION (PAGE 3-109)".
SHIPPING
When shipping the machine on a trailer, do as follows.
● Investigate all state and local laws governing the weight, width, and length of a load. If necessary, disassemble
the work equipment. The width, height and weight of the load differ according to the work equipment, so take
this into account when determining the shipping route.
● When passing over bridges or structures on private land, check first that the structure is strong enough to sup-
port the weight of the machine. When traveling on public roads, check first with the relevant authorities and fol-
low their instructions.
● For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-109)" in the OPERATION section.
2-23
BATTERY
BATTERY HAZARD PREVENTION

Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.
Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.
● Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may
cause an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the
electrolyte level to the UPPER LEVEL line.
● When working with batteries, always wear safety glasses and rubber gloves.
● Do not use a direct air blow or dry cloth to clean the battery.
A wet cloth will prevent fire or explosion from static electricity.
● Never smoke or use any flame near the battery.
● If you spill acid on your clothes or skin, immediately flush

the area with large amounts of water.
● If acid gets into your eyes, flush them immediately with

large quantities of water and seek medical attention.
● Before working with batteries, turn the starting switch to the OFF position.
As there is a hazard that sparks will be generated, always do as follows.
● Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
● Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals
securely.
● Tighten the battery terminals securely.
● Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
● Tighten the battery caps securely.
● Install the battery securely to the determined place.
2-24
STARTING WITH BOOSTER CABLE

If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
● When starting with a booster cable, carry out the starting

operation with two workers (one worker sitting in the opera-
tor's seat and the other working with the battery).
● When starting from another machine, do not allow the two

machines to touch.
● When connecting the booster cables, turn the starting

switch OFF for both the normal machine and problem
machine. There is a hazard that the machine will move
when the power is connected.
● Be sure to connect the positive (+) cable first when install-

ing the booster cables. Disconnect the ground or negative
(-) cable (ground side) first when removing them.
● When removing the booster cables, be careful not to let the

booster cable clips touch each other or to let the clips touch
the machine.
● Always wear safety goggles and rubber gloves when start-

ing the engine with booster cables.
● When connecting a normal machine to a problem machine with booster cables, always use a normal machine
with the same battery voltage as the problem machine.
● For details of the starting procedure when using booster cables, see "STARTING ENGINE WITH BOOSTER
CABLE (PAGE 3-124)" in the OPERATION section.
2-25
TOWING
WHEN TOWING
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec-
tion or inspection of the wire rope.
For towing method, see the section of "TOWING THE MACHINE (PAGE 3-121)".
● Make sure that the towing wire rope and towing bar have the strength at least 1.5 times the working weight
of the machine to be towed.
● Always wear leather gloves when handling wire rope.
● Connect a wire rope to the part indicated with the arrow in

the diagram at right.
● During the towing operation, never stand between the

tow-ing machine and the machine being towed.
● Never tow a machine on a slope.
● 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.
2-26
SAFETY PRECAUTIONS FOR MAINTENENCE
PRECAUTIONS FOR MAINTENENCE
WARNING TAG
● Always attach the "DO NOT OPERATE" warning tag to the
work equipment control lever in the operator's cab to alert
others that you are performing service or maintenance on
the machine. Attach additional warning tags around the
machine if necessary.
Warning tag Part No. 09963-A1640
Keep this warning tag in the tool box while it is not used. If
there is not the tool box, keep the tag in the operation man-
ual pocket.
● If others start the engine, or touch or operate the work

equipment control lever while you are performing service
or maintenance, you could suffer serious injury or property
damage.
KEEP WORK PLACE CLEAN AND TIDY

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

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
When working with others, misunderstandings between workers can lead to serious accidents.
2-27
PRECAUTIONS FOR MAINTENENCE SAFETY
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

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

landslides, or of flooding if the land is low.
● Lower the work equipment completely to the ground and

stop the engine.
● Set work equipment lock lever (1) and brake lock lever (2)
to the LOCK position.
● Put blocks under the track to prevent the machine from

moving.
2-28
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent injury, do not carry out maintenance with the engine
running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and
do as follows.
● One worker must always sit in the operator's seat and be

ready to stop the engine at any time. All workers must
maintain contact with the other workers.
● Set work equipment lock lever (1) and brake lock lever (2)
to the LOCK position.
● 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 extremely careful.
● Do not touch any control levers. If any control lever must

be operated, always give a signal to the other workers to
warn them to move to a safe place.
● Never drop or insert tools or other objects into the fan or

fan belt. Parts may break or be sent flying.
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
NO UNAUTHORIZED PERSONNEL INTO AREA

Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
2-29
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 FOR WORK UNDER MACHINE AND WORK EQUIPMENT

● If it is necessary to go under the work equipment or the
machine to carry out service and maintenance, support the
work equipment and machine securely with blocks and
stands strong enough to support the weight of the work
equipment and machine.
● It is extremely dangerous to work under the machine if the

track shoes are off the ground and the machine is sup-
ported only by the work equipment. If the control levers are
touched by mistake, or there is a hazard to the hydrauli-
cline, the work equipment or the machine may suddenly
descend. This is extremely dangerous. Never work under
the machine if the machine is not properly supported by
blocks or stands.
NOISE
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov-
ers or ear plugs while working.
PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may fly out or metal particles may
be scattered. This may lead to serious injury. Always do as fol-
lows.
● If hard metal parts such as pins, or bearings are hit with a

hammer, there is a hazard that pieces might be scattered
and cause injury. Always wear safety goggles and gloves.
● When hitting pins, 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 pins are hit with strong force, there is a hazard that the pin may fly out and injure people in the surrounding
area.
2-30
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with a proper equip-
ment. There is a hazard of fire or electrocution when carrying out welding, so never allow any unqualified person-
nel to carry out welding.
REMOVING BATTERY TERMINAL

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

TRACK TENSION
● Grease is pumped into the track tension adjustment sys-
tem under high pressure.
If the specified procedure for maintenance is not followed
when making adjustment, grease drain plug (1) may fly out
and cause serious injury or property damage.
● When loosening grease drain plug (1) to loosen the track

tension, never loosen it more than one turn. Loosen the
grease drain plug slowly.
● Never put your face, hands, feet, or any other part of your
body close to grease drain plug (1).
DO NOT DISASSEMBLE RECOIL SPRING

The recoil spring assembly is used to reduce the impact on the idler. It contains a spring under high pressure, so if
it is disassembled by mistake, the spring will fly out and cause serious injury or even death. Never disassemble the
recoil spring.
2-31
PRECAUTION WITH HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury or property damage, so always do as follows.
● Release the pressure. Do not carry out inspection or maintenance when it is under pressure.
● If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the
piping and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
● There is a hazard that high-pressure oil leaking from small

holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly. If you are hit by a jet of high-pres-
sure oil and suffer injury to your skin or eyes, wash the
place with clean water, and consult a doctor immediately
for medical attention.
HANDLING HIGH-PRESSURE HOSES

● If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury or property damage. If any loose bolts are found, stop work and tighten to the specified torque. If any
damaged hoses are found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
● Damaged or leaking hydraulic fitting.
● Frayed or cut covering or exposed reinforcement layer of wire.
● Covering swollen in places.
● Twisted or crushed movable portion.
● Foreign material embedded in covering.
WASTE MATERIAL
To prevent pollution, pay careful attention to the method of disposing of waste materials.
● Always put oil drained from your machine in containers.

Never drain oil directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
● Obey appropriate laws and regulations when disposing of

harmful objects such as oil, fuel, coolant, solvent, filters,
and batteries.
2-32
MAINTENANCE FOR AIR CONDITIONER

If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frost-
bite. Never touch refrigerant.
COMPRESSED AIR
● When carrying out cleaning with compressed air, there is a hazard of serious injury or property damage
caused by flying particles.
● When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.
PERIODIC INSPECTION OF DEFINED LIFE PARTS

● To use the machine safely for a long period, be sure to periodically inspect the defined life parts that have an
especially close relation to safety, such as hoses and the seat belt. If an abnormality is found, replace it
immediately.
● 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 can fail and cause serious personal injury or
death. It is not easy to judge the remaining life of these components but inspect them as much as possible
before work and at the regular maintenance.
● Replace or repair the defined life parts if a defect is found by the check.
2-33
MEMO
2-34
OPERATION
31
WARNING
Please read and make sure that you understand the SAFETY
section before reading this section.
3-1
GENERAL VIEW OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE

Machine equipped with canopy
(1) Blade (7) Sprocket

(2) Tilt cylinder (8) Pivot shaft
(3) Radiator mask (9) Track frame
(4) Lift cylinder (10) Frame
(5) Cab (11) Idler
(6) Track shoe (12) Canopy
3-2
OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES

(1) Fuel control lever (16) Service meter

(2) Cigarette lighter (17) Engine water temperature gauge
(3) Steering, directional and gear shift lever (18) Transmission oil temperature gauge
(4) Air conditioner panel or heater panel (19) Fuel gauge
(5) Head lamp switch (20) Transmission oil temperature caution lamp
(6) Speed range display lamp (21) Monitor caution cancel switch
(7) Starting switch (22) Monitor caution lamp
(8) Rear lamp switch (23) Glow signal lamp
(9) Glow switch (24) Engine oil pressure caution lamp
(10) Brake pedal (25) Charge lamp
(11) Decelerator pedal (26) Engine water temperature caution lamp
(12) Blade control lever (27) Room lamp switch
(13) Horn switch (28) Wiper switch
(14) Work equipment lock lever (29) Additional working lamp switch (if equipped)
(15) Brake lock lever
3-3
GENERAL VIEW OPERATION

Monitor panel specification
(1) Fuel control lever (13) Brake lock lever

(2) Steering, directional and gear shift lever (14) Service meter
(3) Head lamp switch (15) Engine water temperature gauge
(4) Rear lamp switch (16) Transmission oil temperature gauge
(5) Glow switch (17) Fuel gauge
(6) Speed range display lamp (18) Transmission oil temperature caution lamp
(7) Starting switch (19) Monitor caution cancel switch
(8) Brake pedal (20) Monitor caution lamp
(9) Decelerator pedal (21) Glow signal lamp
(10) Blade control lever (22) Engine oil pressure caution lamp
(11) Horn switch (23) Charge lamp
(12) Work equipment lock lever (24) Engine water temperature caution lamp
3-4
OPERATION GENERAL VIEW
Machines equipped with canopy

3 4 5 6 7
8
11
2
1
12
10
13 14
18 17 16 15 G0163803
(1) Fuel control lever (10) Horn switch

(2) Steering, directional and gear shift lever (11) Work equipment lock lever
(3) Head lamp switch (12) Brake lock lever
(4) Rear lamp switch (13) Engine water temperature gauge
(5) Speed range display lamp (14) Transmission oil temperature gauge
(6) Starting switch (15) Glow signal
(7) Brake pedal (16) Engine oil pressure caution lamp
(8) Decelerator pedal (17) Charge lamp
(9) Blade control lever (18) Service meter
3-5
EXPLANATION OF COMPONENTS OPERATION
EXPLANATION OF COMPONENTS
The following is an explanation of the devices needed for operating the machine.
To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the
equipment and the meanings of the displays.
MONITOR PANEL
(Monitor panel specification)
(1) Service meter (7) Engine oil pressure caution lamp

(2) Engine water temperature gauge (8) Glow signal lamp
(3) Transmission oil temperature gauge (9) Transmission oil temperature caution lamp
(4) Fuel gauge (10) Monitor caution lamp
(5) Engine water temperature caution lamp (11) Monitor caution cancel switch
(6) Charge lamp
SERVICE METER
This meter (1) shows the total operation hours of the machine.
Set the periodic maintenance intervals using this display. The
service meter advances while the engine is running, even if the
machine is not traveling.
While the engine is running, the pilot lamp (A) at the top of the
meters keeps flashing to indicate that the meter is advancing.
Meter (B) will advance by 1/10 for each hour of operation
regardless of the engine speed.
3-6
OPERATION EXPLANATION OF COMPONENTS
ENGINE WATER TEMPEARTURE GAUGE

This gauge (2) indicates the cooling water temperature.
When the indicator is in the white range during operation, the

water temperature is normal.
If the indicator moves from the white range into the red range
during operation, stop the machine immediately, run the engine
under no load at a midrange speed, and wait for the indicator to
go down to the white range. After starting the engine, warm up
it until the indicator moves into the white range.
TRANSMISSION OIL TEMPERATURE GAUGE

This meter (3) indicates the temperature of the transmission
lubricating oil.
When the indicator is in the white range during operation, the

oil temperature is normal.
If the indicator moves from the white range into the red range
during operation, stop the machine, run the engine under no
load at a midrange speed, and wait for the indicator to go down
to the white range.
FUEL GAUGE
When the starting switch is turned ON, this meter (4) displays
the amount of fuel remaining in the fuel tank.
F indicates a full tank.
When the indicator points to E, it indicates that there is less

than 43 liters (11.35US gal) remaining, so add fuel.
Always fill the tank after finishing operations.
ENGINE WATER TEMPERATURE CAUTION LAMP

This lamp (5) warns of a rise in the temperature of the engine
cooling water.
If the lamp lights up, stop the machine, run the engine under no
load at a midrange speed, and wait for the indicator of the
engine water temperature gauge (2) to go down to the white
range.
3-7
CHARGE LAMP
This lamp (6) indicates malfunction of the alternator.
When the starting switch is turned ON, it will light up, but it
should go out when the engine speed rises.
If the lamp lights up during operation, stop the engine and

check the V-belt tension. If any abnormality is found, see
"OTHER TROUBLE (PAGE 3-126)".
ENGINE OIL PRESSURE CAUTION LAMP

This lamp (7) warns that the engine lubricating oil pressure has
dropped. When the starting switch is turned ON, it will light up.
When the lamp goes off after the engine is started, the oil pres-
sure is normal.
When the lamp lights up during operation, the oil pressure is

lower. Immediately stop the engine and look for the cause. For
details, see "OTHER TROUBLE (PAGE 3-126)".
GLOW SIGNAL LAMP

This lamp (8) indicates the electrical intake air heater is red-
heated. While preheating is being carried out with the glow
switch, the lamp lights up.
In the case of automatic preheating, the lamp goes out when

the preheating is completed.
In the case of manual preheating, the lamp goes out when the
glow switch is released.
TRANSMISSION OIL TEMPERATURE CAUTION LAMP

This lamp (9) warns the operator that the oil temperature at the
transmission outlet port has risen.
If the lamp lights up, stop the machine, run the engine under no
load at a midrange speed, and wait for the transmission oil
temperature gauge (3) to go down to the white range.
3-8
MONITOR CAUTION LAMP

This lamp (10) lights up when any of the following caution
lamps lights up.
In addition, the alarm buzzer sounds at the same time.
● Engine water temperature caution lamp (5)
● Charge lamp (6)
● Engine oil pressure caution lamp (7)
● Transmission oil temperature caution lamp (9)
MONITOR CAUTION CANCAL SWITCH

This switch (11) is used to cancel monitor caution lamp. Press
the switch to turn the monitor caution lamp out and to stop the
alarm buzzer.
3-9
GAUGE PANEL
(Gauge panel specification)
1 2 3
4 5 6
G0163804
(1) Service meter (4) Charge lamp

(2) Engine water temperature gauge (5) Engine oil pressure caution lamp
(3) Transmission oil temperature gauge (6) Glow signal lamp
SERVICE METER
This meter (1) shows the total number of hours the machine
has operated. Set the periodic service interval using this dis-
play. The service meter advances while the engine is running,
even if the machine is not traveling. Meter will advance by 1 for
each hour of operation regardless of the engine speed.
ENGINE WATER TEMPERATURE GAUGE

This gauge (2) indicates the cooling water temperature. When
the indicator is in the green range during operation, the water Red Green Red
temperature is normal.
If the indicator moves from the green range into the red range
during operation, stop the machine immediately, run the engine
under no load at a midrange speed, and wait for the indicator to
go down to the green range. After starting the engine, warm it
up until the indicator moves into the green range.
G0163805
3-10
TRANSMISSION OIL TEMPERATURE GAUGE

This meter (3) shows transmission lubrication oil temperature.
The temperature is normal, if the needle remains in the green Red Green Red
range while in operation. If the needle goes into the red range
while operating, stop the machine and let the engine idle with
middle rpm and wait until the needle drops to the green range.
℃
G0163806
CHARGE LAMP
This lamp (4) indicates a malfunction of the alternator. When
the starting switch is turned ON, it will light up, but it should go
out as the engine speed rises.
If the lamp lights up during operation, stop the engine and
check the V-belt tension. If any abnormality is found, see
"OTHER TROUBLE (PAGE 3-126)"
ENGINE HYDRAULIC OIL TEMPERATURE CAUTION LAMP

This lamp (5) warns that the engine lubricating oil pressure has
dropped. When the starting switch is turned ON, it will light up.
When the lamp goes off after the engine is started, the oil pres-
sure is normal.
When the lamp lights up during operation, oil pressure is to low.
Immdediately stop the engine and look for the cause. For
details, see "OTHER TROUBLE (PAGE 3-126)"
GLOW SIGNAL
This signal (6) informs the operator that the electrical heater is
red hot.
When the starting switch is held at the HEAT position, the glow
plug becomes red hot in approx. 15 - 45 seconds.
When the key in the starting switch is released, it returns to the
OFF position and the heat goes out.
3-11
SWITCHES
(1) Starting switch (6) Additional working lamp switch

(2) Glow switch (machine equipped with cab) (if equipped)
(3) Horn switch (7) Wiper switch (machine equipped with cab)
(4) Head lamp switch (8) Room lamp (machine equipped with cab)
(5) Rear lamp switch (9) Cigarette lighter (machine equipped with cab)
3-12
STARTING SWITCH
This switch (1) is used to start the engine.
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.
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.
START position:
This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately
after the engine has been started. The key will return to ON position when released.
HEAT position (Gauge panel specification)

Turn the starting switch key to the HEAT position when starting
in cold weather.
If the key is held at the HEAT position, the electrical heater is
heated and the glow signal lights up or glows red. If the glow
signal flashes or glows red, release the key immediately.
When the key is released, it will return to OFF, so turn it imme-
diately to the START position to start the engine.
GLOW SWITCH
This switch (2) actuates the electrical heater to warm up the
engine intake air.
OFF position: The preheating is not actuated.

AUTO position: AUTO preheating is actuated. The length of
the preheating time varies according to the
ambient temperature when the ambient tem-
perature is below approx. -5ºC.
I position: This is used when AUTO preheating is not
enough to start the engine in cold weather sim-
ply with the glows witch at the AUTO position.
When the switch is released, it will return to the
AUTO position.
II position: This is used when carrying out preheating manually without using AUTO preheating.
When the switch is released, it will return to the OFF position.
3-13
HORN SWITCH
The horn sounds when the button (3) at the rear of the blade
control lever at the right side of the operator’s seat is pressed.
HEAD LAMP SWITCH

This switch (4) lights up the head lamps.
OFF position: Lamps are out

ON position: Lamps light up
REAR LAMP SWITCH

This switch (5) lights up the rear lamps.
OFF position: Lamps are out

ON position: Lamps light up
3-14
ADDITIONAL WORK LAMP SWITCH

(Machine equipped with cab) (If equipped)
This switch (6) is used to turn on the additional working lamp.
(A) Head lamp switch

(B) Rear lamp switch
Push in the direction of the arrow to turn on the lamps.
WIPER SWITCH
(Machine equipped with cab)
This switch (7) activates the wipers.
The wiper switches are as follows.
(A) Left door

(B) Front window
(C) Right 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.
3-15
● 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.
ROOM LAMP SWITCH

This lamp is used to turn on and off room lamp (8).
ON position: Lamp lights up

OFF position: Lamp is out
CIGARETTE LIGHTER
This lighter (9) is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its origi-
nal position after a few seconds, so take it out to light your cig-
arette. 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
source for 12 V equipment.If it is used so, the equipment
may be broken.
The capacity of the cigarette lighter is 120W (24V x 5A).
3-16
LAMP
Machine equipped with cab. Following illustration shows machine equipped with air conditioner.
(1) Speed range display lamp
SPEED RANGE DISPLAY LAMP

This lamp (1) indicates the currently selected gear speed
range.
When lamp 1 lights up: 1st

When lamp 2 lights up: 2nd
When lamp 3 lights up: 3rd
3-17
CONTROL LEVERS AND PEDALS
(1) Work equipment lock lever (5) Brake pedal

(2) Brake lock lever (6) Decelerator pedal
(3) Fuel control lever (7) Blade control lever
(4) Steering, directional and gear shift lever
WORK EQUIPMENT LOCK LEVER

WARNING
● When leaving the operator's seat, always set 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 set securely to the LOCK position, the lock may not be applied.
Check that it is in the position shown in the diagram.
● When parking the machine or when carrying out maintenance, always lower the blade to the ground,
then set the work equipment lock lever to the LOCK position.
This lever (1) is a lock device for the work equipment control
levers.
When it is set to the LOCK position, operation of the work
equipment is locked.
If the lever is set to the LOCK position when the blade control
lever is at the FLOAT position, the blade control lever automat-
ically returns to the HOLD position.
3-18
BRAKE LOCK LEVER
WARNING
● When the machine is parked, always set the brake lock lever to the LOCK position.
● If the brake lock lever is operated, the brake operates even while the machine is traveling. Do not
operate the brake lever while the machine is traveling since it stops the machine suddenly, but oper-
ate it only in an emergency.
This lever (2) operates the parking brake. The parking brake is
applied when it is at the LOCK position.
REMARK
● When the steering, directional and gear shift lever is at the
FORWARD or REVERSE position, if the brake lock lever is
operated to the LOCK position, the steering, directional
and gear shift lever will automatically return to the N (neu-
tral) position.
● If the brake lock lever is not at the LOCK position, the limit
switch works and the engine does not start.
FUEL CONTROL LEVER

This lever (3) is used to control the engine speed and output.
(a) Engine stop position:Push the lever forward fully.
(b) Low idling position: Pull the lever from engine stop posi-
tion (a) until you feel the operating
force falls off.
(c) High idling position: Pull the lever fully from low idling posi-
tion (b).
3-19
STEERING, DIRECTIONAL AND GEAR SHIFT LEVER

This lever (4) is used to select the direction of travel, to carry
out steering, and to carry out counterrotation turns.
● Forward-reverse shifting
Position (a): FORWARD

Position (b): REVERSE
Position N: NEUTRAL
● Steering
Position (c): LEFT TURN

Position (d): RIGHT TURN
Move the lever to the FRONT to travel FORWARD
Move the lever to the REAR to travel in REVERSE
If the lever is set in the forward or reverse travel position and

turned to the right or left, the machine turns to the right or left
smoothly according to the stroke of the lever.
If the lever is fully turned to the right or left, the turning radius is
shortened.
REMARK
● If the lever is released when steering the machine, the
lever will return to the (a) position or the (b) position and
the machine will be returned to straight movement.
● If you support the lever guide with your hand when steer-
ing, the turning operation will be easier.
● Gear shifting
Rotate the joystick 30º to carry out gear shifting operation.
Position (e): 1st

Position (f): 2nd
Position (g): 3rd
For the maximum travel speed in each gear speed, see

"SPECIFICATIONS (PAGE 5-2)".
As the gear is shifted, one of the gear speed lamps on the front
panel lights up.
1st: Lamp 1 lights up.

2nd: Lamp 2 lights up.
3rd: Lamp 3 lights up.
3-20
BRAKE PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.
If this pedal (5) is depressed, the left and right brakes are
applied simultaneously.
DECELERATION PEDAL
WARNING
● Do not place your foot on this pedal unnecessarily.
● When passing over the top of a hill or when a load is dumped over a cliff, the load is suddenly
reduced, so there is danger that the travel speed will also increase suddenly. To prevent this, depress
the decelerator pedal to reduce the travel speed.
This pedal (6) is used to lower the engine speed. Depress this
pedal to reduce the speed when shifting between forward and
reverse or when stopping the machine.
3-21
BLADE CONTROL LEVER
POWER TILTDOZER
This lever (7) is used to lift or tilt the blade.
● 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 will not
return to HOLD position, so it must be moved back by
hand.
● If the engine is stopped when the lever is at the FLOAT
position, the control lever will automatically return to the
HOLD position.
● Before starting the engine, check that the blade control
lever is at the HOLD position. The engine will not start
when it is at the FLOAT position.
● In cold weather, it will take time for the lever to be held at
the HOLD position, so hold the lever by hand at the HOLD
position for at least 1 second.
● Tilting control

(e) LEFT TILT
(f) RIGHT TILT
3-22
ANGLEDOZER
This lever (7) is used to raise the blade.
● Lifting control
(a) RAISE:
(c) LOWER:
(d) FLOAT: Blade will move freely according to external force.
REMARK
● When released from FLOAT position, this lever will not
return to HOLD position, so it must be moved back by
hand.
● If the engine is stopped when the lever is at the FLOAT
position, the control lever will automatically return to the
HOLD position.
● Before starting the engine, check that the blade control
lever is at the HOLD position. The engine will not start
when it is at the FLOAT position.
● In cold weather, it will take time for the lever to be held at
the HOLD position, so hold the lever by hand at the HOLD
position for at least 1 second.
3-23
FUSE
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from burning out.
If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the
fuse. Replace a fuse with another of the same capacity.
● Chassis
Fuse boxes (1) and (2) are installed under the battery cover.
● Cab (machines equipped with cab)
Fuse box (3) is installed at the bottom of the overhead panel.
FUSE CAPACITY AND CIRCUIT NAME

Fuse box (1)
No. Fuse capacity Name of circuit
(A) 20A Front lamp, rear working lamp
(B) 10A Chassis power source

(C) 10A Engine control system
(D) 10A Horn
(E) 10A Backup alarm
3-24
Fuse box (2)
(A) 10A Cab radio
(B) 10A Power pitch switching
(C) 20A Air conditioner
(D) — —
(E) 10A Chassis power source
Fuse box (3) (Machine equipped with cab)
(A) 10A Radio memory
(B) 20A Radio, lamp, cigarette lighter
(C) 10A Rear window windshield wiper
(D) 10A Right door windshield wiper
(E) 10A Front window windshield wiper
(F) 10A Left door windshield wiper
3-25
ELECTRIC POWER TAKE-OUT ADAPTER

NOTICE
● Do not use as a power supply for 12V equipment.
This will cause failure of the equipment.
● When using as a power supply pickup, do not install equipment which exceeds 120W (24V x 5A).
1. Open battery cover (1) on the left side of the machine.
2. Pull out the electric power take-out connector for the cab.
(A single-pole connector CN24 (2) for an optional device
can be used.)
Connector CN24 (2) is secured to the main harness with
a band. When using CN24, remove it. After using it,
secure it with the band again.
Capacity of each connector: 480W (24V x 20A)

It is possible to remove the cigarette lighter and use the socket as a power supply.
Capacity of cigarette lighter: 120W (24V x 5A)
REMARK
● Ground the negative wire to the body work or ROPS. Do not ground it to the rubber mounted engine or
valves.This will cause failures.
● If the wire is grounded to a point where there is still paint, the electricity will not flow smoothly, so remove the
paint.
3-26
DOOR-OPEN LOCK
Use this when your want to keep the door held open.
1. Push the door against the door catch (1). The door will be
held by the door catch.
2. To release the door, move lever (2) inside the cab to the
front of the cab. This will release the catch.
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.
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 at the FREE position, the glass can be

opened or closed.
● When the lever is moved to the LOCK (up or down) posi-

tion, the glass is fixed in position.
● If the glass is not held securely, set the lever in the FREE
position and rotate clockwise to strengthen the holding
power.
● To reduce the holding power, turn counterclockwise.
3-27
CAP, COVER WITH LOCK

Use the starting switch key to open and close the caps and
covers.
For their locations, see "LOCKING (PAGE 3-104)".
Insert the key as far as it will go to the shoulder. If the key is
turned before it is inserted all the way, it may break.
METHOD OF OPENING AND CLOSING CAP WITH LOCK
TO OPEN THE CAP

1. Insert the key into the key slot.
2. Turn the key to the OPEN position, align the key slot with
the match mark on the cap, then open the cap.
TO LOCK THE CAP

1. Turn the cap into place and insert the key into the key slot.
2. Turn the key to the LOCK position and take the key out.
3-28
METHOD OF OPENING AND CLOSING COVER WITH LOCK
TO OPEN THE COVER (LOCKED COVER)

1. Insert the key into the key slot.
2. Turn the key counterclockwise and open the cover by

pulling the cover grip.
TO LOCK THE COVER

1. Close the cover and insert the key into the key slot.
2. Turn the key clockwise and take the key out.
HOT AND COOL BOX

This is at the top of the front panel. It can be used to warm or

cool three canned drinks.
This is interconnected with the air conditioner: During heating,

it warms up the drinks; during cooling, it cools to the drinks.
OPERATION MANUAL STORAGE

These are on the inside of the left and right doors, and can be
used for keeping things or Operation & Maintenance manual.
However, do not put tools or other heavy objects in the pocket.

If the pocket becomes dirty, turn three clips (1), remove the
pocket and wash it.
3-29
Machine not equipment with cab
There is a pocket on the back of the operator's seat.
Keep the operation manual in this pocket so that the operator

can read it whenever necessary.
ASHTRAY
This is on the left side of the operator's seat.
Always make sure that you extinguish the cigarette before clos-
ing the lid.
TOOL BOX
The tool box is inside the battery check cover at the rear left.
Keep the tools in this box.
GREASE PUMP HOLDER

This is inside the left engine side cover.
Fit the grease pump to the holder when it is not being used.
3-30
CAR STEREO
(Machine equipped with cab) (If equipped)
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
3-31
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 automati-
cally starts to search for the desired station within a receiv-
able 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
3-32
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 dis-
play" 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.\i
(B) Correcting minute:

Keep the DISP button pressed and press the top (M) of
the TUNING button to correct the minute.\i
3-33
TAPE EJECT BUTTON

This button (7) is used to stop the tape and to eject the cas-
sette.
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.
3-34
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 used also 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 automati-
cally goes up; when the "SEEK DOWN" button is pressed, the
search automatically goes down.
When the next station that can be received is found, it automat-
ically 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.
3-35
METOD 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

seconds.
3. The preset scan tuning function automatically searches

for the desired station within the same band and can
memorize as many as six stations in the preset memory.
METHOD OF MANUAL PRESET

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 dis-
played and the presetting is completed).
4. Repeat the steps explained in Item 2 and 3 above to pre-

set 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
● Use Step 2 to 3 also 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 sta-
tions again.
3-36
LISTENING TO RADIO
1. Turn the starting switch ON, then turn power switch (1)
ON.

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 six stations will broadcast
one after another for five seconds each. When the desired sta-
tion 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 A CASSETE 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 point-
ing 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 finishing with the tape, press the cassette eject

button to eject the tape and automatically switch to the
radio.
3-37
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 abnormality occurs, turn off the
power switch and ask your Komatsu distributor, as soon as possible, to carry repairs.
● 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 benzene, thinner, or any other solvent. Wipe with a soft dry cloth. Use
a cloth soaked in alcohol if the equipment is extremely dirty.
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.
3-38
AIR CONDITIONER
(Machine equipped with cab, air conditioner)
EXPLANATION OF PARTS
(1) Fresh/recirc selector lever (3) Blower switch

(2) Air condition switch (4) Temperature control lever
FRESH/RECIRC SELECTOR LEVER

This lever (1) changes the air intake port used when cooling or
heating.
● RECIRC: If lever (1) is shifted to the left, the air condi-

tioner sucks inside air. Set the lever to this posi-
tion to cool or heat strongly. Ventilation or
pressurizing function is not applied at this posi-
tion.
● FRESH: If lever (1) is shifted to the right, the air condi-

tioner sucks outside air. Set the lever to this
position for normal cooling or heating. In this
position, the cab is ventilated. It is also pressur-
ized to prevent entry of dust.
AIR CONDITION SWITCH

When the switch (2) is pressed and the blue lamp lights up, the
cooling function is actuated. Use this switch for cooling or
dehumidifying.
3-39
BLOWER SWITCH
This switch (3) acts as the wind flow control switch and main
switch when cooling or heating.
● The air flow can be set to three stages:

1 (LOW) → 2 (MEDIUM) → 3 (HIGH).
● If the switch is set to 0, the power is switched off and the air
conditioner stops.
TEMPERATURE CONTROL LEVER

This lever (4) is used to control the temperature for cooling or
heating.
● When the temperature control lever is moved to the right,

the temperature of the air coming from the vents becomes
lower. (The water valve is closed and the heating function
is stopped.)
● When the temperature control lever is moved to the left,

higher. (The water valve is opened and the heating function
is started.)
3-40
COOLING OPERATION
When the cooling operation is carried out, the inside of the cab is cooled, and at the same time the drinks inside
the hot and cool box can be cooled.
COOLING (RECIRC)
When the control switch and lever are operated as shown in
the diagram, a cool breeze is sent out. Use this position when
strong cooling is needed.
● Press switch (2).
● Place levers (1) and (4) in the position shown in the dia-
gram.
● Set switch (3) to the desired position.
COOLING (FRESH)
If the air inside the cab is no longer fresh, set FRESH/RECIRC
selector lever 1 to FRESH to bring in fresh air. Keep the other
switches at the same positions as for cooling (RECIRC). In this
position, the inside of the cab is pressurized to prevent the
entry of dust.
REMARK
If the cooling effect is reduced, set FRESH/RECIRC selector
lever (1) to RECIRC again. This increases the cooling effect.
3-41
HEATING OPERATION
When the heating operation is carried out, the inside of the cab is heated, and at the same time the drinks inside
the hot and cool box can be heated.
HEATING (RECIRC)
When the control switch and lever are operated as shown in
the diagram, warm air is sent out. Use this position when
strong cooling is needed.
● Place levers (1) and (4) in the position shown in the dia-
gram.
HEATING (FRESH)
If the air inside the cab is no longer fresh, set FRESH/RECIRC
selector lever (1) to FRESH to bring in fresh air. Keep the other
switches at the same positions as for heating (RECIRC). In this
position, the inside of the cab is pressurized to prevent the
entry of dust.
REMARK
If the cab is not heated up sufficiently, turn FRESH/RECIRC
selector lever (1) back to RECIRC. This increases the heating
effect.
DEHUMIDIFYING AND HEATING

Push switch (2). When temperature control lever (4) is placed
at the central position, dry warm air blows out.
Keep the other switches at the same positions as for heating

(FRESH).
REMARK
If this is used in spring and fall on rainy days when the air
inside the cab is damp, there is no problem of the windows
misting up, and the cab be warmed up to a comfortable tem-
perature.
3-42
PREVENTION METHOD OF ENTRY OF DUST

Entry of dust into the cab can be prevented by starting the blower fan for the air conditioner to raise the pressure in
the cab a little higher than outside.
When working in a dusty job site or when preventing dust from entering the cab, use this function.
● Close the windows and doors.
● Set lever (1) to the FRESH position.
● Set switch (2) to any of positions 1, 2, or 3.
● Set lever (4) to the desired position.
PRECAUTION WHEN USING AIR CONDITIONER
CARRY OUT VENTILATION FROM TIME TO TIME WHEN USING THE COOLER.
● If you smoke when the cooler is on, the smoke may start to hurt your eyes, so turn the lever to FRESH to
remove the smoke while continuing the cooling.
● When the air conditioner is used for long periods, carry out ventilation once every hour.
BE CAREFUL NOT TO MAKE THE TEMPERATURE IN THE CAB TO LOW.

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

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

Even during the off-season, run the compressor at low speed for several minutes once a week to prevent the loss
of the oil film at the lubricated parts of the compressor. (Run the engine at low speed and set the temperature con-
trol lever at the central position.)
REMARK
When the ambient temperature is low, if the compressor is suddenly run at high speed, it may cause failure of the
compressor. Note that the system is set so that the compressor will not run when the cooler switch is turned on if
the ambient temperature is less than 2 to 6.5ºC.
3-43
PROCEDURE FOR REPLACING RECEIVER

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

If the air filter for the FRESH or RECIRC air intake becomes clogged, the cooling or heating capacity will drop. In
places where there is a lot of dust, clean the air with compressed air once a week. For details of the cleaning
method, see "CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (PAGE 4-56)".
3-44
HEATER
(Machine equipped with cab, heater)
EXPLANATION OF PARTS
(1) FRESH/RECIRC selector lever (3) Temperature control lever

(2) Blower switch
FRESH/RECIRC SELECTOR LEVER

This lever (1) changes the air intake port used when cooling or
heating.
● RECIRC: If lever (1) is shifted to the left, the air conditioner

sucks inside air. Set the lever to this position to
cool or heat strongly. Ventilation or pressurizing
function is not applied at this position.
● FRESH: If lever (1) is shifted to the right, the air condi-

tioner sucks outside air. Set the lever to this posi-
tion for normal cooling or heating. In this
position, the cab is ventilated. It is also pressur-
ized to prevent entry of dust.
BLOWER SWITCH
This switch (2) acts as the wind flow control switch and main
switch when cooling or heating.
● The air flow can be set to three stages:

1 (LOW) → 2 (MEDIUM) → 3 (HIGH).
● If the switch is set to 0, the power is switched off and the

heater stops.
3-45
TEMPERATURE CONTROL LEVER

This lever (3) is used to control the temperature for heating.
● When the temperature control lever is moved to the right,

lower.
● When the temperature control lever is moved to the left,

higher.
METHOD OF OPERATION
TO HEAT QUICKLY
Set the switches to the position shown in the diagram on the
right to carry out heating quickly
● Set FRESH/RECIRC selector lever (1) and temperature

control lever (3) to the position in the diagram on the right.
● Set blower switch (2) to position 3 (HIGH).
NOTICE
If heating is carried out continuously for a long period with
the lever at the RECIRC position, the air inside the cab will
become stale, so when the cab is warmed up, always set
the FRESH/RECIRC selector lever (1) to the FRESH posi-
tion.
In this position, the inside of the cab is pressurized to pre-
vent the entry of dust.
MORNAL USE
Set each switch to the desired position.
PREVENTION METHOD OF ENTRY OF DUST

Entry of dust into the cab can be prevented by starting the blower fan for the heater to raise the pressure in the cab
a little higher than outside.
When working in a dusty job site or when preventing dust from entering the cab, use this function.
● Close the windows and doors.
● Set lever (1) to the FRESH position.
● Set lever (3) to the desired position.
3-46
CREANING AIR FILTER

If the air filter for the FRESH or RECIRC air intake becomes clogged, the heating capacity will drop.
In places where there is a lot of dust, clean the air with compressed air once a week. For details of the cleaning
method, see "CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (PAGE 4-56)".
3-47
OPERATION OPERATION
OPERATION
CHECK BEFORE STARTING ENGINE, ADJUST
WALK-AROUND CHECK
Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leak-
age 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.
WARNING
● Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as
the engine muffler or turbocharger, may cause fire.
Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.
● Do not get on or off the machine from the rear. Using this position is dangerous because it is easy to
slip and you cannot be seen from the operator's compartment. Always use the handrail and step at
the side when getting on or off the machine.
If the machine is at an angle, make it horizontal before checking.
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 that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses.
If any abnormality is found, repair it.
2. Remove the dirt from around the engine and radiator.
Check that there is no dirt accumulated around the engine or radiator. Check also that there is no flammable
material (dry leaves, twigs, etc.) around the engine muffler, turbocharger, or other high temperature parts of
the engine. If any dirt or flammable materials are found, remove them.
3. Check for leakage of water or oil around engine
Check that there is no leakage of oil from the engine or leakage of water from the cooling system. If any
abnormality is found, repair it.
4. Cleaning around battery
Make sure that there is no dirt, especially electrolyte such as snow melting agent or salt on the battery, and
no deposits around the battery.
Do the cleaning around the battery.
For how to handle the battery such as cleaning precautions, see "BATTERY (PAGE 2-24)".
Also, do not use a direct air blow or dry cloth to clean the battery. Use a wet cloth to prevent fire or explosion
from static electricity.
5. Check for oil leakage of oil from power train case, final drive case, hydraulic tank, hose, joints
Check that there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking
Check for leakage of oil from the undercover. Check the ground for traces of oil leakage.
3-48
OPERATION OPERATION
6. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers
If any abnormality is found, repair it.
7. Check for damage to handrail, loose bolts
If any abnormality is found, repair it. Tighten any loose bolts.
8. Check for damage to gauges, lamps on instrument panel, loose bolts
Check that there is no damage to the panel, gauges and lamps. If any abnormality is found, replace the
parts. Clean off any dirt on the surface.
9. 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.
3-49
OPERATION OPERATION
CHECK BEFORE STARTING

Always carry out the items of the checks in this section before starting the engine each day.
CHECK COOLANT LEVEL, ADD WATER
WARNING
● Do not open the radiator cap unless necessary. When checking the coolant, always wait for the
engine to cool down and check the sub tank.
● 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.
1. Open the engine side cover on the left side of the chas-
sis, and check that the coolant is between the FULL and
LOW marks on sub-tank (1). If the water level is low, add
water to the FULL level through the water filler port in
sub-tank (1).
REMARK
In summer, the coolant may overflow from the sub-tank drain
hose. This is no problem. It occurs because too much coolant
has been added.
2. After adding water, tighten the cap securely.
3. If the sub-tank is empty, check for leakage of water, then

add water to the radiator and sub-tank.
4. After adding water, close the engine side cover.
3-50
OPERATION OPERATION
CHECKING WITH MACHINE MONITOR

(Monitor panel specification)
1. Turn starting switch (1) to the ON position.
2. Check that all monitor lamps light up for 3 seconds, the

warning lamp lights up for 2 seconds, and the alarm
buzzer sounds for 1 second.
REMARK
If the lamps do not light up, there may be a failure or discon-
nection in the monitor, so please contact your Komatsu distrib-
utor.
3-51
OPERATION OPERATION
CHECK SPEED RANGE DISPLAY LAMP

1. Turn starting switch (1) to the ON position.
2. Check that only one of speed range display lamps (2) is

lighting.
3. Operate steering, directional and gear shift lever (3) to

shift the gear, and check that the lighting lamp changes
according to the operation.
Position (a): 1st

Position (b): 2nd
Position (c): 3rd
REMARK
If any lamp does not light up or two or more lamps light up, or if
the lighting lamp does not change even the gear is shifted, the
gear speed lamp system or its wire may be broken. In this
case, call your Komatsu distributor and ask for inspection.
3-52
OPERATION OPERATION
CHECK FUEL LEVEL, ADD FUEL
WARNING
When adding fuel, never spill the oil or let it overflow. It can catch fire. If any fuel is spilled, wipe it up com-
pletely. If fuel has spilled over soil or sand, remove that soil or sand.
Fuel is highly flammable and dangerous. Never bring flames near fuel.
1. Turn the engine starting switch to the ON position and

check the fuel level with fuel level gauge (G) on the mon-
itor panel. After checking, turn the switch back to the OFF
position.
2. After completing work, fill the fuel tank through fuel filler
port (F).
Fuel tank capacity: 410 liters (108US gal)
3. After adding fuel, tighten the cap securely.
NOTICE
If breather hole (1) in the cap is clogged, the pressure
inside the tank will drop and fuel will not flow. Clean
breather (1) from time to time and check that it is not
clogged.
GAUGE PANEL SPEC.

1. Remove the cap and check the fuel level using fuel
gauge (G).
2. After completing work, fill the fuel tank through fuel filler
port (F).
Fuel capacity: 410 liters (108 US gal)
3. After adding fuel, tighten the cap securely.
3-53
OPERATION OPERATION
NOTICE
If breather hole (1) in the cap is clogged, the pressure
inside the tank will drop and fuel will not flow. Clean
breather (1) from time to time and check that it is not
clogged.
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait
for the temperature to go down before starting the operation.
sis.
2. Remove dipstick (G) and wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.
4. The oil level should be between the H and L marks on

dipstick (G).
If the oil level is below the L mark, add engine oil through
oil filler (F).
5. If the oil is above the H mark, drain the excess engine oil
from drain plug (P), and check the oil level again.
6. If the oil level is correct, tighten the oil filler cap securely
and close the engine side cover.
REMARK
● If the machine is at an angle, make it horizontal before checking.
● When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the
engine before checking.
3-54
OPERATION OPERATION
CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL
WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait
for the temperature to go down before starting the operation.
1. Open cover at the right side of the machine.
2. Remove dipstick (G), and wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.
4. The oil level should be between the H and L marks on

dipstick (G).
If the oil level is below the L mark, add engine oil through
oil filler (F).
5. If the oil is above the H mark, drain the excess engine oil
from drain plug (P), and check the oil level again.
6. If the oil level is correct, tighten the oil filter cap securely.
REMARK
● When checking the oil level after the engine has been
operated, wait for at least 15 minutes after stopping the
engine before checking.
● If the machine is at an angle, make it horizontal before
checking.
CHECK BRAKE PEDAL TRAVEL
WARNING
If the brake pedal stroke is not 70 to 90mm (2.8 to 3.5in)
(below 70mm or over 90mm), the brake and steering force
is too strong or insufficient. If the stroke is 91mm (3.6in)
or longer, adjust it.
1. Depress the brake pedal all the way until it stops.
2. The distance of travel at the center of the pedal should be

70 to 90mm (2.8 to 3.5in).
3. When this value exceeds 91mm (3.6in), or the brake fails

to work, please contact your Komatsu distributor for
adjustment.
3-55
OPERATION OPERATION
CHECK DUST INDICATOR

sis, and check that the red piston has not appeared in the
transparent portion of dust indicator (1).
2. If the red piston has appeared, clean or replace the ele-

ment immediately.
For details of the method of cleaning the element, see
"CHECK, CLEAN AND REPLACE AIR CLEANER ELE-
MENT (PAGE 4-19)".
3. After checking, cleaning, and replacing, press the knob of

dust indicator (1) to return the red piston to its original
position.
CHECK ELECTRIC WIRING
WARNING
● If the fuses frequently blow or if there are traces of short circuits on the electrical wiring, locate the
cause immediately and carry out repairs, or contact your Komatsu distributor for repairs.
● 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 clean the breather hole.
Check that there is no damage to the fuses and that a fuse of the correct capacity is being used. Check that there
are no disconnections or traces of short circuits on the electrical wiring, and no damage to the covering. Check
also that there are no loose terminals.
Be particularly careful to check the wiring of the battery, starting motor, and alternator.
Always check also that there is no flammable material accumulated around the engine. Remove any such flamma-
ble material.
Please contact your Komatsu distributor for advice on investigation and correction of the cause.
3-56
OPERATION OPERATION
CHECK THAT LAMPS LIGHTS UP

Check that the head lamp, rear lamp, additional working lamp (if equipped), and instrument lamp light up normally
and they are free from stain and damage.
If the lamps do not light up, there is probably a broken bulb or disconnection in the wiring, so contact your Komatsu
distributor for repairs.
1. Insert the key into starting switch and turn the key to the
ON position.
2. Turn the head lamp switch, the rear lamp switch and the
additional working lamp to the ON position and check
that the head lamps and rear lamps light up.
3. Turn the additional head and rear working lamp switches

(optional) to the ON position, and check that all the lamps
light up.
3-57
OPERATION OPERATION
DOES THE HORN SOUND NORMALLY?

Check that the horn sounds. If it does not sound at all or the sound is extremely feeble, a defect or broken wire is
suspected, ask your Komatsu distributor for possible repairs.
ON position.
2. Push the horn switch and check that the horn sounds.
CHECK BACKUP ALARM SOUND

Check that the backup alarm sounds normally. If it does not, a defect or broken wire is suspected, ask your
Komatsu distributor for possible repairs.
ON position.
3-58
OPERATION OPERATION
2. Set the brake lock lever to the FREE position.
3. Set the steering, directional and gear shift lever in the

REVERSE position.
The buzzer must sound immediately at this time. The
buzzer keeps sounding until the steering, directional and
gear shift lever is set to the NEUTRAL or FORWARD
position.
3-59
OPERATION OPERATION
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER

(If equipped)
The water separator separates water mixed in the fuel. If float

(2) is at or above red line (1), drain the water according to the
following procedure.
1. Loosen drain plug (3) and drain the accumulated water

until the float reaches the bottom.
2. Tighten drain plug (3).
3. If the air is sucked into fuel line when draining and water,
be sure to bleed air in the same manner as for the fuel fil-
ter. See "REPLACE FUEL FILTER CARTRIDGE (PAGE
4-57)".
3-60
OPERATION OPERATION
ADJUSTMENT
ADJUST OPERATOR'S SEAT
WARNING
● Adjust the seat position at the beginning of each shift or when operators change.
● Adjust the seat so that the brake pedal can be depressed all the way 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 oper-
ate, then release the lever.
Fore-aft adjustment: 160mm (6.3in) (8 stages)
(B) Weight adjustment of seat
Turn knob (2) under the seat to match the weight adjustment
scale with your own weight.
The weight can be adjusted to 50 to 120kg (110 to 265lb).
REMARK
If you want to make the seat softer, turn the weight adjustment
to a lower weight; if you want to make the seat harder, adjust to
a higher weight.When operating on uneven surfaces, adjust the
seat to a harder setting.
(C) Adjuster reclining angle
NOTICE
When reclining the seat back to the rear, check the space
behind, and adjust to a suitable position.
Pull lever (3), set the seatback to a position where it is easy to operate, then release the lever.
(D) Seat angle adjustment
● Front angle adjustment of seat (5 stages)
To raise the front of the seat, apply your weight to the seat back, pulling up lever (4).
To lower the front of the seat, apply your weight to the front of the seat, pulling up lever (4).
● Rear angle adjustment of seat (5 stages)
To raise the rear of the seat, stand up on your feet a little, pulling up lever (5).
To lower the rear of the seat, apply your weight to the rear of the seat, pulling up lever (5).
(E) Seat height adjustment
Pull up levers (4) and (5) alternately to adjust the angle of the seat.
Then, release the levers to lock the seat. (Height adjustment distance: 5 stages, 60mm (2.4in))
3-61
OPERATION OPERATION
ADJUST ARM REST

The height of the armrests on both sides of the operator's seat
can be adjusted to three levels. After adjusting the operator's
seat, adjust the height of the armrests properly.
1. Loosen knobs (1) on both sides of the operator's seat.
2. Move the armrests on both sides of the operator's seat

forward, then adjust their height to (H), (M), or (L).
(H): High
(M): Medium
(L): Low
3. Move back both armrests.
4. Tighten knobs (1) securely.
3-62
OPERATION OPERATION
USING SEAT BELT

Always install a seat belt on machines equipped with ROPS.
WARNING
● Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting
belt of the belt. If the belt is worn or damaged, replace it.
● Replace the seat belt every three years, even if their outside is free from abnormality. The year of man-
ufacture is woven on the back side of the belt.
● Always fasten the seat belt before starting operations.
● Always use the seat belt during operations.
● Do not twist the left or right side of the seat belt when fastening it.
Check that the bolts of the clamp securing the belt to the chassis are not loose. Tighten them if they are loose. The
tightening torque for the mounting bolt is 24.5 ± 4.9 N•m (2.5 ± 0.5 kgf•m,18.1 ± 3.6 lbft).
If the belt surface is scratched or frayed or if the fittings are broken or deformed, replace the seat belt unit.
FASTENING AND REMOVING BELT

1. Sit on the seat, depress the brake pedal fully, and adjust the seat so that your back is pressed against the
backrest.
2. After adjusting the seat position, adjust tether belt (1).

Tense the tether belt and install it when there is no one
sitting on the seat.
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 first.
5. Pull the belt to check that it is securely locked in position.
6. When removing the belt, press the red button on buckle (3).
The belt will automatically be wound in.
3-63
OPERATION OPERATION
OPERATION AND CHECK BEFORE STARTING ENGINE
WARNING
● When starting the engine, check that the work equip-
ment lock lever is securely at 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 accident.
● When standing up from the operator's seat, always set

the work equipment lock lever to the LOCK position,
regardless of whether the engine is running or
stopped.
1. Check that the brake pedal is locked with brake lock lever
(1). If this lever is not at the LOCK position, the engine
will not start.
3-64
OPERATION OPERATION
2. Insert the key into starting switch (2) and turn the key to
the ON position.
3. Check that speed range display lamp (3) shows 1st.
4. Check that steerling, directional and gear shift lever (4) is

at the N (neutral) position.
5. Check that the blade is lowered to the ground and that

blade control lever (5) is at the HOLD position.
6. Check that the work equipment lock lever (6) is locked.
3-65
OPERATION OPERATION
STARTING ENGINE
NORMAL STARTING
WARNING
● Check that there are no persons or obstacles in the
surrounding area, then sound the horn and start the
engine.
● Exhaust gas is toxic. When starting the engine in con-

fined spaces, be particularly careful to ensure good
ventilation.
NOTICE
● Do not start the engine with the fuel control lever near
the FULL position.
There is danger that this will damage the engine parts.
● Do not keep the starting motor rotating continuously
for more than 20 seconds.
If the engine will not start, wait for at least 2 minutes
before trying to start the engine again.
1. Before starting the engine, check that fuel control lever

(1) is at the low idling position.
2. Pull fuel control lever (1) to a position midway between

the low idling and full speed positions.
the START position. The engine will start.
3-66
OPERATION OPERATION
4. When the engine starts, release the key in starting switch

(2). The key will return automatically to the ON position.
5. Continue idling for 10 seconds after the engine starts. During this time, do not operate the control levers or
fuel control lever.
STARTING IN COLD WEATHER
WARNING
● Check that there are no persons or obstacles in the surrounding area, then sound the horn and start
the engine.
● Never use starting aid fluids as they may cause explosions.
When starting in low temperatures, do as follows.
NOTICE
the FULL position.
If the engine fails to start, repeat steps 2 and 3 after
waiting for about 2 minutes.
3-67
OPERATION OPERATION


the ON position.
4. Carry out preheating.

There are the following two ways of carrying out preheating. First use the convenient automatic preheating
system.
For operating method, see the section of "AUTOMATIC PREHEATING (PAGE 3-69)" and "MANUAL PRE-
HEATING (PAGE 3-70)".
3-68
OPERATION OPERATION
AUTOMATIC PREHEATING
1. Turn glow switch (3) to the AUTO position.
When it is turned to the AUTO position, preheating is
automatically carried out according to the ambient tem-
perature. Lamp (4) lights up during the preheating opera-
tion. When the preheating is completed, lamp (4) will go
out.
2. When the preheating is completed, turn the key in start-

ing switch (2) to the START position to start the engine.

fuel control lever.
5. After starting the engine, return glow switch (3) to the

OFF position.
REMARK
If the engine can not start after automatic preheating, start it
using manual preheating.
3-69
OPERATION OPERATION
MANUAL PREHEATING
1. Turn glow switch (3) to position I or II.
Lamp (4) lights up during the preheating operation.
When the preheating is completed, release the switch.
The key will then return automatically to the following
position.
From position I, it will return to AUTO
From position II, it will return to OFF
The preheating times are as shown below.
Ambient temperature Preheat time
0ºC to -5ºC
-
(32°F to 23°F)
-5ºC to -10ºC
15 seconds
(23°F to 14°F)
-10ºC to -20ºC
30 seconds
(14°F to -4°F)
-20ºC to -30ºC
45 seconds
(-4°F to -22°F)
If the preheating time is too long or too short, the engine will not start easily. Observe the correct preheating time.
2. When the preheating is completed, turn the key in start-

ing switch (2) to the START position to start the engine.

fuel control lever.
3-70
OPERATION OPERATION
GAUGE PANEL SPEC.
NOTICE
the FULL position.
If the engine fails to start, repeat steps 2 and 3 after
waiting for about 2 minutes.
3 G0163807


3. Insert the key into starting switch (2), turn the key of start-
ing switch (2) to the HEAT position and hold it until glow
signal (3) glows red.
3-71
OPERATION OPERATION
The preheating times are as shown below.
Ambient temperature Preheat time
0ºC to -5ºC
-
(32°F to 23°F)
-5ºC to -10ºC
15 seconds
(23°F to 14°F)
-10ºC to -20ºC
30 seconds
(14°F to -4°F)
-20ºC to -30ºC
45 seconds
(-4°F to -22°F)
If the preheating time is too long or too short, the engine will not start easily. Observe the correct preheating time.
4. When glow signal becomes red, turn the starting switch

key (2) to the START position to start the engine.

fuel control lever.
3-72
OPERATION OPERATION
OPERATIONS AND CHECKS AFTER STARTING ENGINE
BREAKING IN THE NEW MACHINE
CAUTION
Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating
the machine under severe conditions at the beginning can adversely affect the performance and shorten
the machine life.
Be sure to running-in the machine for the initial 100 hours (as indicated by the service meter).
During running-in operations, follow the precautions described in this manual.
Precautions for running-in

● Idle the engine for 5 minutes after starting it up.
● Avoid operation with heavy loads or at high speeds.
● Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency.
WARMING UP OPERATIONS
After starting the engine, do not immediately start operations.
First, carry out the following operations and checks.
NOTICE
Avoid abrupt acceleration until warm-up run is completed.
Do not run the engine at low idling or high idling for more
than 20 minutes. If it is necessary to run the engine at
idling, apply a load or run at a medium speed from time to
time.
3-73
OPERATION OPERATION
1. Pull fuel control lever (1) to the center position between

LOW IDLING and HIGH IDLING and run the engine at
medium speed for about 5 minutes with no load.
2. After warm-up has completed, check gauges and caution

lamps for proper operation. If any abnormality is found,
repair it.
Continue to run the engine at low load until engine water
temperature gauge (2) falls within the white range (Moni-
tor Panel Spec.) or green range (Gauge Panel Spec.).
3. Check that there is no abnormal exhaust gas color, noise,

or vibration. If any abnormality is found, repair it.

2
G0163808
3-74
OPERATION OPERATION
STARTING IN COLD WEATHER

After starting the engine, do not immediately start operations.
First, carry out the following operations and checks.
NOTICE
Avoid abrupt acceleration until warm-up run is completed.
Do not run the engine at low idling or high idling for more
than 20 minutes. If it is necessary to run the engine at
idling, apply a load or run at a medium speed from time to
time.

the low idling and full speed positions, run the engine at a
mid-range speed, and continue to run under no load for
approx. 10 minutes.
2. Operate blade control lever (3) fully to the RAISE posi-

tion, then hold the lever in position, and operate slowly to
the left tilt relief and right tilt relief in turn for 5 minutes.
3. After this, operate the blade control lever (3) fully to the
RAISE position, hold the lever in position, and relieve the
left and right tilt intermittently. Next, operate the lever to
the LOWER position and lower the blade to the ground,
then operate the lever fully to the FLOAT position, hold
the lever in position, and relieve the left and right tilt in
turn intermittently for 5 minutes.
4. Next, depress the brake pedal and move the brake lock lever from the LOCK position to the FREE position.
(Keep in this condition when carrying out the operation in Step 5.)
5. Lower the blade to the ground, operate the control lever fully to the FLOAT position (lever stroke end) and
hold the lever in position by hand for 1 minute. Next, release the lever and check that it is held at the FLOAT
position. After waiting for 3 minutes, return the lever to the HOLD position.
3-75
OPERATION OPERATION
REMARK
If the work equipment oil is not up to operating temperature, the response of the work equipment or steering may
be slow, the lever may become heavy or may not return properly. Also, if the blade control lever is set to the
FLOAT position and released immediately, the lever may return to the HOLD position.
6. After warm-up has completed, check gauges and caution

lamps for proper operation. If any abnormality is found,
repair it.
Continue to run the engine at low load until engine water
temperature gauge (2) falls within the white range (Moni-
tor Panel Spec.) or green range (Gauge Panel Spec.).
7. Check that there is no abnormal exhaust gas color, noise,

or vibretion. If any abnormality is found, repair it.

2
G0163808
AIR CONDITIONER WARM-UP OPERATION
NOTICE
To prevent the failure of the air conditioner compressor, do the warm-up operation of the air conditioner
one time a day when you use the air conditioner for the first time. If you turn on the air conditioner while
the engine runs at high speed, the excessive load is applied to the air conditioner compressor, and it can
cause the seizure in the air conditioner compressor.
If you use it while the air conditioner switch is in the ON position, make the conditions as follows for 3 minutes after
the air conditioner is started.
1. Set the fuel control lever (at the 1/4 position between the
low idling position and high idling position).
2. Set the temperature to minimum and the air flow to maximum,
and continue for 3 minutes.
The air conditioner compressor starts up securely, and the
warm-up operation of the air conditioner is done.
3-76
OPERATION OPERATION
STOPPING ENGINE
NOTICE
If the engine is abruptly stopped before it has cooled
down, engine life may be greatly shortened. Consequently,
do not abruptly stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly
stop it but run it at medium speed to allow it to cool gradu-
ally, then stop it.
1. Place fuel control lever (1) in the low idling position and
run the engine at low idling speed for about 5 minutes to
allow it to gradually cool down.
2. Place fuel control lever (1) in the engine stop position and
stop the engine.
3. Turn the key in starting switch (2) to the OFF position and
remove the key from starting switch (2).
3-77
OPERATION OPERATION
CHECK AFTER STOPPING ENGINE

1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, and check
also for leakage of oil or water. If any abnormalities are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud affixed to the undercarriage.
3-78
OPERATION OPERATION
MACHINE OPERATION
MOVING MACHINE OFF
WARNING
● When starting the machine off, check that the area
around the machine is safe and sound the horn before
moving.
Do not allow people to enter the area around the
machine.
The area at the rear of the machine is a blind spot, so
be extremely careful when reversing the machine.
● When starting the machine off on slopes, always keep

brake pedal (2) depressed, even after setting brake
lock lever (1) to the FREE position.
● When starting the machine on a steep uphill slope,

pull fuel control lever (7) fully to run the engine at full
throttle. Keep brake pedal (2) depressed, set steering,
directional, and gearshift lever (4) to the 1st gear posi-
tion, then set steering, directional, and gearshift lever
(4) to the direction of travel. Release brake pedal (2)
slowly, and when the machine starts to move slowly
(or the shoes slip), release brake pedal (2) completely.
● For machines equipped with a backup alarm, check

that the backup alarmsounds when steering, direc-
tional and gear shift lever (4) is placed in REVERSE.
1. Set brake lock lever (1) to the FREE position.
3-79
OPERATION OPERATION

the desired position, and check that speed range display
lamp (3) shows the correct position.
3. Pull the work equipment lock lever (6) to the free position.
4. Put blade control lever (5) in the RAISE position to raise

the blade 40 to 50mm (1.6 to 2.0in) off the ground.
5. Move steering, direction and gear shift lever (4) to the F

(forward) or R (reverse) position to move the machine off.
6. Pull fuel control lever (7) to increase engine speed.
3-80
OPERATION OPERATION
STOPPING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when
stopping.
1. Depress brake pedal (1) to stop the machine.
2. Place steering, directional and gear shift lever (2) in the N

(neutral) position.
3-81
OPERATION OPERATION

1st, and check that speed range display lamp (3) shows
the correct position.
3-82
OPERATION OPERATION
SHIFTING GAER
There is no need to stop machine to shift gears.
1. Set steering, directional and gear shift lever (1) in the

desired position to shift gear.
● Gear shifting
Rotate Steering, directional and gear shift lever 30º to carry out
gear shifting operation.
Position (a): 1st gear

Position (b): 2nd gear
Position (c): 3rd gear
For the maximum travel speed in each gear speed, see

"SPECIFICATIONS (PAGE 5-2)".
As the gear is shifted, one of the gear speed lamps on the front
panel lights up.
1st: Lamp 1 lights up.

2nd: Lamp 2 lights up.
3rd: Lamp 3 lights up.
3-83
OPERATION OPERATION
SHIFTING BETWEEN FORWARD AND REVERSE
CAUTION
The travel direction can be changed without stopping the
machine. Do not change it while the engine is running at
the full speed, however, but depress the decelerator pedal
to lower the engine speed before changing the travel
direction for safety, comfort, and longer life of the power
train.
1. Set fuel control lever (1) to the LOW IDLING position or

depress decelerator pedal (2) to reduce the engine
speed.
2. Depress brake pedal (3) to apply the brake.
3. Move steering, directional and gear shift lever (4) to the N

(neutral) position, depress brake pedal (3) further, and
stop the machine.
3-84
OPERATION OPERATION
4. Shift steering, directional and gear shift lever (4) to the

desired position.
5. Pull fuel control lever (1) or release decelerator pedal (2)

to raise the engine speed.
6. For machines equipped with a backup alarm, check that the backup alarm sounds when steering, directional
and gear shift lever (4) is placed in REVERSE. If the alarm does not sound, please contact your Komatsu
distributor.
3-85
OPERATION OPERATION
STEERING MACHINE
WARNING
● Avoid as much as possible turning the machine on a slope. The machine will tend to slip sideways.
Particular care should be taken on soft or clay land.
● Never try to turn the machine sharply when traveling at high speed.
NORMAL TURNING
To turn the machine while traveling, incline steering, directional
and gear shift lever (1) in the direction to turn.
3-86
OPERATION OPERATION
TURNING TO LEFT WHILE TRAVELING FORWARD

If the steering, directional and gear shift lever (1) is pushed for-
ward and moved partially to the left (L), the machine will start to
turn gradually. After that, the lever can be moved further toward
the end of its stroke to give the desired turning radius.
REMARK
ward and moved partially to the right, the machine will start to
turn gradually to the right. After that, the lever can be moved
further toward the end of its stroke to give the desired turning
radius. Do the same when traveling in reverse.
3-87
OPERATION OPERATION
TURNING WHILE DESCENDING A SLOPE
WARNING
This machine cross-steers when it descends a steep slope where it is driven down by its own weight or
when it is pushed down by a towed machine on a slope. Accordingly, descend a slope as explained
below.
REMARK
Cross steering means the phenomenon that the machine turns in the opposite direction to the actual steering
direction.
WHEN TURNING TO THE LEFT GRADUALLY WHILE TRAVELING FORWARD

ward and moved partially to the right (R), the machine turns
gradually to the left. (Becomes reverse steering)
REMARK
When turning to the right gradually while traveling forward,
push the steering, directional and gear shift lever (1) forward,
and move it partially to the right. (Becomes reverse steering)
Do the same when traveling in reverse.
3-88
OPERATION OPERATION
WHEN MAKING A PIVOT TURN TO THE LEFT WHILE TRAVELING

ward and moved fully to the left (L), the machine turns sharply
to the left. (Does not become reverse steering)
REMARK
When making sharp turns to the right, push the steering, direc-
tional and gear shift lever (1) forward, and move it fully to the
right. (Does not become reverse steering)
Do the same when traveling in reverse.
3-89
OPERATION OPERATION
PERMISSIBLE WATER DEPTH

When operating in water, always keep the bottom of carrier
roller (1) 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.
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS
USE ENGINE AS BRAKE

When going downhill, shift gear shift lever into low speed to run engine at slow speed and travel down slope using
the engine as a brake.
Never coast down slope with the steering and directional lever in the N (neutral) position.
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.
PRECAUTIONS ON SLOPES
BE CAREFUL OF FUEL LEVEL

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

If the engine stops while working or driving on a slope, the brake is applied automatically. Take care since the
machine stops suddenly at this time.
IT IS 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.
3-90
OPERATION OPERATION
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT

OBSTRUCT THE VIEW
● For safety reasons, do not install anything to the cab glass that will obstruct the view.
● Always keep the glass clean to ensure safety during operations.
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY
WARNING
The cab stay cause blind spots.
When operating, always be sure to check carefully that
there is no obstacle or worker in the surrounding area.
3-91
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.
When dozing toward one side only, operate with angled blade
(angledozer only).
SMOOTHING
NOTICE
Avoid smoothing on rocky or stony ground. It can damage
the blade.
To finish the ground to a flat surface after digging or leveling,

put a full load of soil in front of the blade and operate the blade
up and down in small movements while traveling forward.
Finally, place the blade at FLOAT and travel at low speed in
reverse while pulling the blade over the ground surface. Before
doing this, hold the lever by hand at the FLOAT position for at
least 1 second to make sure that it stays in position. To prevent
damage to the blade, be careful not to travel over any stones or
rocks.
3-92
OPERATION OPERATION
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.
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 30cm (3.9 to 11.8in), 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.
3-93
OPERATION OPERATION
ADJUSTING POSTURE OF WORK EQUIPMENT
ADJUST ANGLE OF BLADE EDGE

WARNING
It is dangerous if the work equipment moves by mistake when adjusting angle of the blade edge. Set the
work equipment in a stable condition, then stop the engine and lock the work equipment securely with the
work equipment lock lever.
Adjust the angle (θ) of the blade edge to match the type of soil.
POWER TILTDOZER
Power tiltdozer with screw-adjustable tilt brace.
Turn the brace with bar handle (1) and the distance (¬)
between the joints to change the cutting angle (θ) as follows.
INCREASE distance (¬) to INCREASE angle (θ).
DECREASE distance (¬) to DECREASE angle (θ).
The standard for the cutting angle (θ) is 55º.
The standard for the distance between the joints is shown
below (¬).
¬ = 1150 mm (45.3 in)
REMARK
It is impossible to adjust blade angle of stable tilt brace.
ANGLEDOZER
CAUTION
The angle of the blade edge of the angledozer blade can not be adjusted.
If the angle of the blade edge is changed by changing the brace length, an excessive bending stress will
be applied to the center pin, which may be broken.

The standard for the distance between the joints is shown below (¬).
¬ = 1374 mm (54.1 in)
3-94
OPERATION OPERATION
ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT

When assembling the work equipment, if the adjustment of the play is not carried out properly, excessive bending
stress will be generated at all parts, and this will lead to cracks or breakage.
Adjust the play of parts (1) to (4) to the correct value. For details, see "ADJUSTING SHIMS, ADJUSTING TEN-
SION AT WORK EQUIPMENT LINKS (PAGE 4-38)".
● When disassembling the machine for transportation, be careful not to lose the shims.
Shim adjusting
position (1) (2) (3) (4)
Tilt Lift Center Trunnion
Item
0.2 - 0.7 0.2 - 0.7 0.2 - 0.7 0.2 - 1.2
Optimum mm
(0.008 - (0.008 - (0.008 - (0.008 -
value (in)
0.028) 0.028) 0.028) 0.047)
Thickness
mm 5 4 5 10
of standard
(in) (0.197) (0.158) (0.197) (0.4)
shims
● Power tiltdozer
● Semi U-dozer
● Angledozer
ADJUSTING TENSION OF CENTER BRACE

(Power tilt dozer)
(Semi-U dozer)
If the work equipment assembly is removed for transportation and is assembled again after transportation, the ten-
sion of the center brace must be adjusted. If this is not done, the bushing at the connecting part of the blade and
straight frame will come out, and sand and soil will enter. This will cause premature wear or damage of the bush-
ing.
Adjust the tension of the center brace. For details, see "ADJUSTING SHIMS, ADJUSTING TENSION AT WORK
EQUIPMENT LINKS (PAGE 4-38)".
3-95
OPERATION OPERATION
ADJUSTING BRACE OF ANGLE BLADE
WARNING
It is dangerous if the work equipment moves by mistake when it is being adjusted. Move the machine to a
horizontal place, stop the machine, and set the work equipment in a stable condition. Then stop the
engine and set the work equipment lock lever securely to the LOCK position.
CAUTION
The purpose of the brace length adjustment mechanism of the angle blade is to adjust the tilt of the blade.
If this adjustment is not performed properly, the work equipment may be cracked or broken.
ADJUSTING ARM LENGTH

Adjust arm length (A) to a proper value according to the following procedure.
1. Pull out pins (1) (3 pieces).
2. Remove arm (2).
3. You can adjust arm length (A) by loosening lock bolts (3).
Adjust arm length (A) to a proper value.
Proper value: 1,709 ± 10 mm
4. Return arm (2) and pins (1).
3-96
OPERATION OPERATION
ADJUSTING BRACE FOR USING BLADE IN STANDARD POSTURE
CAUTION
If the brace is not adjusted to a proper length, an excessive bending stress may be applied to the center
pin, which may be broken.
1. Raise the blade up to the height of 400 mm to 500 mm

(15.8 in to 19.7 in) above the ground, and put block (A)
beneath the blade edge.
2. Loosen set bolt (1) of the brace.
3. Insert a suitable bar into hole (2) of the brace and turn it
to adjust length (B) of the brace.
Adjust respective lengths (B) of the right and left braces

to the following length.
1,374 ± 10 mm
4. Tighten set bolt (1).
3-97
OPERATION OPERATION
ADJUST AMOUNT OF TILT POWER TILT

(Angledozers only)
WARNING
When adjusting the amount of tilt, 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
NOTICE
An amount of tilt (A) can be increased to a maximum of
400 mm (15.8 in).
Adjust an amount of tilt (A) within 400 mm (15.8 in).
1. Raise the blade up to the height of 400 mm to 500 mm

(15.8 in to 19.7 in) above the ground, and put block (B)
beneath the blade edge.
3-98
OPERATION OPERATION
2. Loosen the bolt (1) of the brace, insert a suitable bar into
hole (2) of the brace, and turn it.
CAUTION
Do not adjust only either brace.
If the length of only either brace is changed to adjust the
tilt, an excessive bending stress may be applied to the
center pin, which may be broken.
Be sure to lengthen either brace and shorten the opposite
one by the same
REMARK
When turning the brace with bar, keep the blade above the
ground.
Right tilt: Make right side shorter, left side longer

Left tilt: Make left side shorter, right side longer
When the tilt is adjusted to the maximum, length (C) of the brace is as shown in the following table.
Max. tilt Brace length (C) (mm)

Model
(mm) Shortened side Lengthened side In standard posture
D85ESS 400 1,320 1,425 1,374
3. Tighten set bolt (1).
3-99
OPERATION OPERATION
METHOD OF ANGLING BLADE

(Angledozers only)
When dozing toward one side only, operate with angled blade.
WARNING
● When adjusting the amount of angling, 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
● Be careful when removing arm (2). After arm (2) is

removed, the blade can move freely.
1. Raise the blade 300 to 400 mm (11.8 to 15.8 in) above

the ground, then put blocks under the frame so that the
blade does not come down.
2. Remove pins (1) on the left and right sides, then remove
arm (2) from the frame.
3-100
OPERATION OPERATION
3. Insert arm (2) into the desired position on the bracket on

top of the frame (3 places on each side), and insert pins
(1).
ADJUSTING TILT FOR USING BLADE IN ANGLED POSTURE

(Angledozers only)
Perform the following adjustment to adjust the brace length properly.
1. Return the blade to the standard posture (non-angled posture).
2. Adjust the blade to the necessary tilt.
3. Angle the blade.
3-101
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 lever 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 acci-

dent, the work equipment may move suddenly, and
this may lead to a serious accident. Before leaving the
operator’s seat, always operate the work equipment
lock lever to place it securely at the LOCK position.
1. Stop the machine. For details, see "STOPPING MACHINE (PAGE 3-81)".
2. Set brake lock lever (1) to the LOCK position and apply
the parking brake.
3-102
OPERATION OPERATION
3. Operate blade control lever (2) to the LOWER position,

and lower the blade to the ground.
4. Set work equipment lock lever (3) to the LOCK position.
CHECK AFTER FINISHING WORK

Use the meters and caution lamps to check the engine water
temperature, engine oil pressure, fuel level, and transmission
oil temperature.
G0163809
3-103
OPERATION OPERATION
LOCKING
To prevent vandalism, there are locks at the following places.
Places that can be locked with the starting switch key.
● Top cover at front of chassis (1)
● Right and left engine side cover (2)
● Battery inspection cover (3)
● Inspection cover for fuel tank drain valve (4)
● Cab door opener (5) (machines equipped with cab)
● Fuel tank filler cap (6)
● Hydraulic tank filler cap (7)
3-104
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.
Please consult your Komatsu distributor when selecting track shoes.
● Do not allow shoe slipping to occur during operation.
If shoe slipping occurs, reduce load to the blade until slipping stops.
● Avoid sudden starts, acceleration or stops, unnecessarily high speeds and sharp turns.
● Always operate machine in a straight line whenever possible. When making turns, be careful not to allow the
machine to stay to one side, so operation in both turning directions can be done properly. Make turns with the
largest possible radius.
● Prior to operation, clear boulders and obstacles to prevent machine from riding over them while operating.
● On a slope, operate the machine parallel to the inclination

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

tion, do not continue to dig with machine inclined. Move
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 dur-
ing dozing or ripping operations.
3-105
OPERATION OPERATION
INSPECTION AND ADJUSTMENT

● Properly adjust track tension.
Check the track tension by measuring clearance A

between the idler and carrier roller shown in the figure at
right. Clearance A should be 20 to 30mm (0.8 to 1.2in) nor-
mally. Tense the track a little more for operation on rocky
terrain and loosen it a little for operation on clayey terrain.
Carrying out operations when the track is excessively
loose may cause abnormal vibration and abnormal wear of
the sprocket teeth.
(For inspection and adjustment procedures, refer to
"CHECK TRACK TENSION (PAGE 4-26)").
● Check idler rollers for oil leakage as well as for loose bolts
and nuts. If any trouble is detected, repair immediately.
● Check clearance (B) between the idler guide plate and

track frame. If clearance (B) increases, idler may move
sideways and the tracks may come off. (For inspection and
adjustment procedure, refer to "ADJUST IDLER CLEAR-
ANCE (PAGE 4-37)".)
3-106
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. Per-
form periodical inspection and contact the Komatsu distributor in your area when machine has approached repair-
able limits and reversing limits.
MEASURING LINK PITCH

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

more than 2 links away from master pin. Of length
obtained, 1/4 is the link pitch.
● Basic link pitch (P): 203 mm (8 in)
● Link pitch limit for turning: 206 mm (8.1 in)
There is no link window on the master link.
REMARK
The measured value after the decimal point for the link pitch may be different from basic link pitch (P), even if there
is no wear. This depends on the tolerance for the machining dimensions and the precision of measurement. Do
not immediately judge that there is wear; take measurements periodically and judge from the trend.
MEASURING HEIGHT OF GROUSER

After taking up slack in track shoes, measure height at center
of shoe as shown below.
● Standard height (h): 65 mm (2.6 in)
● Repair limits: 25 mm (1 in)
3-107
OPERATION OPERATION
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): 210 mm (8.3 in)
● Repair limits: 172 mm (6.8 in)
3-108
OPERATION TRANSPORTATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
TRANSPORTATION MEANS
As a rule, transport the machine on a trailer, as a rule.
Select a trailer according to the mass and dimensions of the machine shown in "SPECIFICATIONS (PAGE 5-2)".
Note that the mass and dimensions for transportation shown in SPECIFICATIONS depend on the types of shoe,
blade, etc.
REMOVING CAB
If it is necessary to remove the cab for transportation, there is danger that the seal may be damaged when remov-
ing or installing the cab, so please contact your Komatsu distributor.
When installing the cab, please contact your Komatsu distributor, too.
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT

If there is any pressure remaining in the tilt piping after the work equipment has been removed, it may be difficult to
remove the quick coupler of the tilt hose, so remove the work equipment as follows.
1. Lower the blade to the ground and set it horizontal to the

ground surface.
REMARK
If the blade is tiled, the tilt piping will be under internal pressure,
so set the blade horizontal to the ground.
2. Remove the quick coupler, then remove the work equip-

ment assembly.
3-109
TRANSPORTATION OPERATION
3. Remove the left and right trunnions.
4. Tie the tilt hose with a band to prevent it from being dam-
aged.
3-110
LOADING, UNLOADING WORK
WARNING
● Since loading and unloading of the machine is dangerous, be extremely careful.
● When loading or unloading the machine, operate it slowly with the engine speed low and the trans-
mission in the 1st gear.
● Use ramps having sufficient width, length, thickness, and strength. Install them securely and set their
angle to 15º or less. If the ramps are deflected largely, reinforce them with blocks.
● Perform the loading work of the machine on a level and hard place. Secure sufficient distance
between the shoulder of the road and the trailer.
● Remove mud from the undercarriage of the machine so that the machine will not slip sideways on the
ramps. In addition, remove water, snow, ice, grease, oil, etc. from the ramps.
● Never steer the machine on the ramps, since steering on the ramps can cause rolling of the machine.
If it is necessary to change the travel direction, return to the ground or to the bed of the trailer, then
change the travel direction.
● 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 boarder slowly.
When loading or unloading, always use ramps or a platform and carry out the operation as follows.
LOADING
1. Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of a road.
2. Properly apply the brakes on the trailer and put blocks

under the tires to ensure that the trailer does not move.
Then fix the ramps in line with the centers of the trailer
and the machine.
Be sure that the two sides are at the same level as one
another. Make the slope of the ramps a maximum of 15º.
Set the distance between the ramps to match the center
of the tracks.
3. Start the engine.

When starting in cold areas, carry out the warming-up operation. For details, see "STARTING IN COLD
WEATHER (PAGE 3-75)".
4. Set the work equipment lock lever to the FREE position.
5. Raise the blade.
7. Set the transmission in the 1st gear and run the engine at low idling speed.
3-111
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 boarder slowly.
10. Stop the machine at the specified position on the trailer.
SECURING MACHINE
WARNING
When the edge of the blade protrudes beyond the trailer, angle the blade. (Angledozer)
NOTICE
Be sure to retract the car radio antenna (if the machine equipped with cab).
Load the machine on to a trailer as follows.
1. Lower the work equipment slowly.
2. Lock blade control levers securely with the work equip-

ment lock lever.
3. Set the brake lock lever to the LOCK position.
4. Set the fuel control lever to the ENGINE STOP position to

stop the engine, then turn the starting switch to the OFF
position and remove the key.
5. Fix the machine as explained below so that it will not move during transportation.
In particular, fix the machine securely to prevent it from slipping sideways.
3-112
1) Put blocks in front and behind the track shoes of

both sides.
2) Set up chain or wire, following (A) or (B).
● A:Set up chain or wire through the holes of track

links.
● B:Set up chain or wire around the track shoes.
3) Protect the wire from contacting directly with angular

parts of the machine, by inserting pads.
3-113
UNLOADING
1. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road.
2. Properly apply the brakes on the trailer and put blocks

under the tires to ensure that the trailer does not move.
Then fix the ramps in line with the centers of the trailer
and the machine.
Be sure that the two sides are at the same level as one
another. Make the slope of the ramps a maximum of 15º.
Set the distance between the ramps to match the center
of the tracks.
3. Remove the chains or wire rope holding the machine.

When starting in cold areas, carry out the warming-up
operation.
For details, see "STARTING IN COLD WEATHER (PAGE
3-75)".
5. Set the work equipment lock lever to the FREE position.
6. Raise the blade.
8. Set the transmission in the 1st gear and run the engine at
low idling speed.
9. Set the travel direction toward the ramps and drive

slowly.
10. 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 boarder slowly.
11. Drive down the ramps slowly and carefully until the machine leaves the ramps perfectly.
3-114
LIFTING MACHINE
WARNING
● Do not lift the machine with any worker on it.
● Use wire ropes having sufficient strength for the weight of this machine.
● Lift the machine in only the position shown below. If it is lifted in another position, it may be unbal-
anced.
● Lift the machine horizontally.
NOTICE
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to the attachments and options actually installed. In such cases,
please contact your Komatsu distributor for information.
For details of the weight, see "SPECIFICATIONS (PAGE 5-2)".
PROSEDURE FOR LIFTING OPERATIONS
3-115
For machine equipped with ripper
When lifting the machine, stop it on a level place, then observe the following procedure.
1. Stop the engine and set the brake lock lever to the LOCK
position.
2. Install wire ropes, slings, etc. matched to the weight of

the machine to the lifting points as shown in the above
figure.
NOTICE
● Use protectors, etc. so that the wire ropes will not be
broken at sharp edges or narrow places.
● Use sleds and bars having sufficient width so that they
will not touch the machine.
3. 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 horizontal, then lift up slowly.
3-116
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 fol-
lows.
FUEL AND LUBRACANTS

Change to oil with low viscosity for all components. For details of the specified visicosity, see "RECOMMENDED
FUEL, COOLANT, AND LUBRICANT (PAGE 4-11)".
COOLANT
WARNING
● Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes
or on your skin, wash it off with large amounts of fresh water and see a doctor at once.
● When changing the coolant or when handling coolant containing antifreeze that has been drained
when repairing the radiator, please contact your Komatsu distributor or request a specialist company
to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto
the ground surface.
● Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze.
NOTICE
● Use Komatsu Supercoolant wherever available, or use permanent type antifreeze coolant.
● Never use methanol, ethanol, or propanol-based antifreeze.
● Do not use any water leakage prevention agent, either alone, or in combination with antifreeze.
● Do not mix one brand of antifreeze with a different brand.
For details on the amount of antifreeze mixture and on when to change the coolant, see "CLEAN INSIDE OF
COOLING SYSTEM (PAGE 4-23)".
3-117
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 large amounts
of water, and consult a doctor.
● Battery electrolyte dissolves paint. If it gets on to 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 charge rate from the following conversion table.
Electrolyte
Temperature 20ºC 0ºC -10ºC -20ºC
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.
3-118
OPERATION COLD WEATHER OPERATION
AFTER COMPLETION OF WORK

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, 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 morn-
ing.
● 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 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 4-11)".
3-119
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 a sheet.
● 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 sepa-
rately.
● Place all control levers at the neutral position, operate the safety lever and parking lever to the LOCK position,
then move the fuel control lever to the low idling position.
To prevent corrosion, be sure to fill the cooling system with Supercoolant (AF-NAC) or permanent type anti-
freeze (density between 30% and 68%).
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.
● Before operating the work equipment, wipe the grease off the hydraulic piston rod.
● 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.
3-120
OPERATION TROUBLESHOOTING
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL

When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before starting. For
details of bleeding the air, see "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-57)".
TOWING THE MACHINE
WARNING
● Make sure that the towing wire rope has the strength at least 1.5 times the working weight of the
machine to be towed.
● When using the towing hook, be sure to use a shackle.
● Set the wire rope horizontally and align it with the track frame.
● Tow the machine slowly.
NOTICE
The allowable towing load of this machine is 14,123 kg (138,500 N).
Do not tow any load greater than this.
Put the wire rope on the position shown by the arrow in the figure.
When you use wire rope, chain, or link for the towing work,
wind it around the cross bar.
Do not tow the machine with the force 1.5 times or more of the
working weight in this case.
3-121
TROUBLESHOOTING OPERATION
For details of the method of towing, contact your Komatsu distributor.

• If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic
system, the brake works and the machine cannot move. To move the machine in this case, the oil pressure
in the brake circuit must be heightened to the specified level with a special device. Contact your Komatsu
distributor.
• Moving a machine by towing is only used to move it to a place where it is possible to perform inspection
and maintenance. Do not tow it a long distance.
• If it is impossible to operate the steering and brakes of the machine being towed, do not let anyone ride on
the machine.
• Keep the angle of the towing line to the minimum. Operate the machine so that the angle does not become
greater than 10° from the straight travel direction.
3-121-1
3-121-2
IF BATTERY IS DISCHARGED
WARNING
● 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

haz-ard of explosion. Do not bring lighted cigarettes
near the battery, or do anything that will cause sparks.
● Battery electrolyte is dilute sulphuric acid, and it will

attack your clothes and skin. If it gets on your clothes
or on your skin, wash it immediately off with large
amounts of water. If it gets in your eyes, wash it out
with fresh water, and consult a doctor.
● When handling batteries, always wear protective gog-

gles 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.
● If the terminals are loose, there is danger that the

defective contact may generate sparks that will cause
an explosion.
● When removing or installing the terminals, check

which is the positive (+) terminal and which is the neg-
ative (-) terminal.
● Green rust around the terminals is a cause of self-dis-

charge of the battery. Polish the terminals with sand-
paper. After removing the rust, coat the terminals
thinly with grease before installing.
● For the removal and installation of battery, see

“REMOVE AND INRTALL BATTERY (PAGE 3-123) ”.
3-122
REMOVE AND INSTALL BATTERY

1. Open battery cover (1), remove 4 bolts (2) on the inside,
then remove cover (1).
2. Before removing battery, remove the ground cable (nor-

mally 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 of
the terminal and remove the wires from the battery.
3. After installing the battery, fix it with the battery fitting

securely.
Tightening torque: 1.47 to 1.96 N•m

(0.15 to 0.2 kgf•m, 1.1 to 1.4 lbft)
4. When install the battery, connect the ground cable last. Insert the hole of the terminal on the battery and
tighten the nut.
Tightening torque: 5.88 to 9.81 N•m (0.6 to 1.0 kgf•m, 4.3 to 7.2 lbft)
5. Install battery cover (1).
PRECAUTIONS FOR CHARGING BATTERY

If the battery is charged improperly, it may explode. Accord-
ingly, charge it according to "IF BATTERY IS DISCHARGED
(PAGE 3-122)" and the instruction manual attached to the
charger, and observe the following items.
● Set the voltage of the charger to match the voltage of the

battery to be charged. If the voltage is not selected cor-
rectly, 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 nega-
tive (-) charger clip of the charger to the negative (-) termi-
nal of the battery. Be sure to fix the clips securely.
● Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging,
set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire
and explode.
● If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery electrolyte and cause the battery to explode.
● Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may
cause an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the
electrolyte level to the UPPER LEVEL line.
3-123
STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE
WARNING
● When connecting the cables, never contact the posi-
tive (-) and negative (+) terminals.
● When starting the engine with a booster cable, always

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 mistaken 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 brake lock levers of both machines are in the LOCK
positions respectively.
● Check that each lever is in the neutral position.
CONNECTING THE BOOSTER CABLE

Keep the starting switch of the normal machine and problem
machine are both at the OFF position.
Connect the booster cable as follows, in the order of the num-
bers marked in the diagram.
1. Connect one clip of booster cable (A) to the positive (+)

terminal of the problem machine.
2. Connect the other clip of booster cable (A) to the positive

(+) terminal of the normal machine.
3. Connect one clip of booster cable (B) to the negative (-)

terminal of the normal machine.
4. Connect the other clip of booster cable (B) to the engine block of the problem machine.
3-124
STARTING ENGINE
CAUTION
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 at the HOLD or neu-
tral position.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and keep it to run at high idling speed.
3. Turn the starting switch of the problem machine to the START position and start the engine. If the engine
doesn't start at first, try again after 2 minutes or so.
DISCONNECTING THE BOOSTER CABLE

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

block of the problem machine.
2. Remove the other clip of booster cable (B) from the nega-
tive (-) terminal of the normal machine.
3. Remove one clip of booster cable (A) from the positive

(+) terminal of the normal machine.
4. Remove the other clip of booster cable (A) from the posi-
tive (+) terminal of the problem machine.
3-125
OTHER TROUBLE
ELECTRICAL SYSTEM
● ( ): Always contact your Komatsu distributor when dealing with these items.
● In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.
Problem Main causes Remedy

Lamp does not glow brightly even when ● Defective wiring ( ● Check, repair loose terminals, dis-
the engine runs at high speed connections)
● Defective adjustment of fan belt ten- ● Adjust fan belt tension For details,
Lamp flickers while engine is running
sion see EVERY 250 HOURS SERVICE
Charge lamp does not go out even when ● Defective alternator ( ● Replace)
engine is running ● Defective wiring ( ● Check, repair)
Abnormal noise is generated from alter- ● Defective alternator ( ● Replace)
nator
● Defective wiring ( ● Check, repair)
Starting motor does not turn when start-
● Insufficient battery charge ● Charge
ing switch is turned to ON
● Safety switch out of adjust ( ● Adjust safety switch)
Pinion of starting motor keeps going in ● Insufficient battery charge ● Charge
and out
Starting motor turns engine sluggishly
● Defective starting motor ( ● Replace)
Starting motor disengages before engine ● Defective wiring ( ● Check, repair)
starts ● Insufficient battery charge ● Charge

Automatic preheating is not actuated ● Defective glow switch ( ● Replace)
● Defective timer ( ● Replace)
Glow signal lamp dose not go out
● Defective heater relay ( ● Replace)
Glow signal lamp does not become red
● Defective heater relay ( ● Replace)
(gauge panel specification only)
● Defective glow signal ( ● Replace)
Oil pressure caution lamp does not light ● Defective caution lamp ( ● Replace)
up when engine is stopped (starting ● Defective caution lamp switch ( ● Replace)
switch at ON position) ● Defective wiring ( ● Check, repair)
Charge lamp does not light up when ● Defective charge lamp ( ● Replace)
engine is stopped (starting switch at ON ● Defective wiring ( ● Check, repair)
position)
● Disconnection in electrical intake air ( ● Replace)
Outside of electrical intake air heater is
heater
not warm when touched by hand
● Defective operation of heater relay ( ● Check, repair heater relay switch)
switch
● Blown fuse ( ● Check, repair)
Air conditioner does not work properly ● Defective air conditioner switch ( ● Replace air conditioner switch)
● Defective blower switch ( ● Replace blower switch)
● Defective compressor ( ● Replace)
Speed range display lamp does not light
● Defective limit switch ( ● Replace)
up.
● Defective display lamp ( ● Replace)
Speed range display lamp does not ● Defective wiring ( ● Check, repair)
change when gear is shifted. ● Defective limit switch ( ● Replace)
3-126

Blade does not pitch when pitch is oper-
● Defective switch ( ● Replace)
ated (pitch specification only)
● Defective solenoid valve ( ● Replace)
3-127
CHASSIS
repairs.
When brake pedal is depress, ● Brake out of adjust, defective ( ● Adjust, check, repair)
machine does not stop brake oil pressure
Track comes off ● Track too loose ● Adjust track tension, see
WHEN REQUIRED
Abnormal wear of sprocket ● Track too loose or too tightened
● Lack of hydraulic oil ● Add oil to specified level, see

EVERY 250 HOURS SER-
Blade, rises slowly, dose not rise VICE
● Work equipment lock lever in ● Set lever in free position
LOCK position
● Brake lock lever in LOCK posi- ● Set lever in free position
Dose not steer even when steering tion
or operated ● Defective hydraulic pressure at ( ● Check, repair)
steering clutch
● Lack of oil in idler ● Add oil to specified level, see

Noise is generated from idler
WHEN REQUIRED
Blade control lever is not held at ● Insufficient warming up ● Carry out warming-up operation
FLOAT position
● Wear, scuffing of gear pump ( ● Check, repair)
● Lack of oil in power train case ● Add oil to specified level, see
Transmission oil pressure dose not CHECK BEFORE STARTING
rise ● Element strainer of oil filter in ● Clean
power train case clogged For details, see EVERY 1000
HOURS SERVICE
Lacks drawber pull (cannot travel ● Lack of drive power from engine ● See ENGINE RELATED
at full speed) PARTS
● Low temperature of power line oil ● Warm up machine

Travel speed does not rise quickly ● Lack of drive power from engine ● See ENGINE RELATED
PARTS
Machine dose not move off when ● Transmission oil pressure dose ● See "Transmission oil pres-
steering, directional and gear shift not rise sure dose not rise" above
lever is placed in gear ● Brake lock lever in LOCK posi- ● Set lever in free position
tion
● Wear, scuffing of gear pump ( ● Check, repair)
3-128
● Transmission oil pressure dose ● See "Transmission oil pres-
Torque converter overheats not rise sure dose not rise" above
(indicator enters red range) ● Wear, scuffing of gear pump (● Check, repair)
● Excessive load when operating ● Shift down one position, or
reduce the load and increase
the speed when operating
3-129
ENGINE
repairs.
● 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 caution lamp
500 HOURS SERVICE
remains alight when engine speed is
● Defective tightening of oil pipe (● Check, repair)
raised after completion of warm-up
joint, oil leakage from damaged
part
● Defective caution lamp ( ● Replace)
● Cooling water level low, water ● Add cooling water, repair, see
leakage CHECK BEFORE STARTING
● Loose fan belt ● Adjust fan belt tension, see
Steem is emitted from top part of
EVERY 250 HOURS SERVICE
radiator (pressure valve)
● Dirt or scale accumulated in cool- ● Change cooling water, clean
ing system inside of cooling system, see
WHEN REQUIRED
● Clogged radiator fin or damaged ● Clean or replace, see WHEN
fin REQUIRED
Indicator of water temperature ● Defective thermostat (● Replace thermostat)
gauge is in red range on right side of ● Loose radiator filler cap (high ● Tightening cap or replace pack-
gauge altitued operation) ing
● Defective water temperature (● Replace water temperature
gauge gauge)
Indicator of water temperature ● Defective thermostat ( ● Replace thermostat)
gauge is in white range on left side ● Defective water temperature ( ● Replace water temperature
of gauge gauge gauge)
● Lack of fuel ● Add fuel, see CHECK BEFORE
STARTING
● Air in fuel system ● Repair place where air is sucked
in
● Defective fuel injection pump or (● Replace pump or nozzle)
Engine dose not start when starting
nozzle
motor is turned
● Starting motor cracks engine slug- ● See ELECTRICAL SYSTEM
gishly
● Glow signal dose not glow red ● See ELECTRICAL SYSTEM
● Defective compression
● Defective valve clearance ( ● Adjust valve clearance)
● Too mach 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 black
● Defective nozzle (● Replace nozzle)
● Defective compression (● Adjust valve clearance)
Combustion noise occasionally ● Defective nozzle ( ● Replace nozzle)
makes breathing sound
3-130
● Low grade fuel being used ● Change to specified fuel

● Overheating ● See item "Indicator of water tem-
Abnormal noise generated perature gauge is in red range
(combustion or mechanical) on right side of gauge"
● Damage inside muffler (● Replace muffler)
● Excessive valve clearance (● Adjust valve clearance)
3-131
MEMO
3-132
MAINTENANCE
41
WARNING
Please read and make sure that you understand the safety
volume before reading this section.
4-1
GUIDE TO MAINTENANCE MAINTENANCE
GUIDE TO MAINTENANCE
Do not carry out any inspection and maintenance operation that is not found in this manual.
CHECK SERVICE METER

Check the service meter reading every day to see if the time has come for any necessary maintenance to be car-
ried out.
KOMATSU GENUINE REPLACEMENTPARTS:

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

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

Use automobile windshield washer fluid, and be sure 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.
CHECKING FOREIGN MATERIALS DRAINED OIL:

After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If
large quantities 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:
● Turn off the engine starting switch.
● Do not apply more than 200V continuously.
● Connect grounding cable within 1m (3.3 ft) from the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may have troubles.
● Avoid seals or bearings from being between the area to be welded and the position of grounding point.
● Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
4-2
MAINTENANCE GUIDE TO MAINTENANCE
DO NOT DROP THINGS INSIDE MACHINE:

● 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 will cause damage and 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.
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 get-
ting into the oil.
AVOID MIXING OILS:

Never mix different kinds of oil. If a different type of oil has to be added, drain the old oil and replace all the oil with
the new type of oil.
PRECAUTIONS FOR OPENING AND CLOSING ENGINE SIDE COVER

● Open the engine side cover all the way and ensure it is
locked open before letting go.
● When standing on the track to open the engine side cover,

bend at the knees and open the cover in a standing posi-
tion to avoid back strain.
● Close the engine side cover before opening or closing the

cab door.
4-3
GUIDE TO MAINTENANCE MAINTENANCE
LOOKING THE INSPECTION COVERS:

When carrying out maintenance with the inspection cover open, lock it in position securely with a lock bar. If
inspection or maintenance is carried out with the inspection cover open and not locked in position, there is a haz-
ard that it may be suddenly blown shut by the wind and cause injury to the worker.
HYDRAULIC SYSTEM - AIR BLEEDING

After repairing or replacing the hydraulic equipment or after removing the hydraulic piping, it is necessary to bleed
the air from the circuit. For details, see "PROCEDURE FOR BLEEDING AIR OF HYDRAULIC SYSTEM (PAGE 4-
37)".
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 into loops with a small radius.
This will cause damage to the hose and markedly reduce its service life.
CHECK AFTER INSPECTION AND MAINTENANCE WORKS:

If you forget to carry out the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious injuly or property damage. Always do as follows.
● Checks after operation (with engine stopped)
● Have any inspection and maintenance points been forgotten?
● Have all inspection and maintenance items been carried out correctly?
● Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside machine and get caught in the lever linkage mechanism.
● Is there any leakage of water or oil? Have all the 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 2-29)" 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.
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE

Select the fuel and lubricants to match the ambient temperature.
For details, see "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (PAGE 4-11)".
4-4
MAINTENANCE OUTLINE OF SERVICE
OUTLINE 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, when the machine is shipped from the factory, it is filled with the oil and coolant
listed in the table below.
Item Type
Engine oil pan Engine oil EO15W40DH (Komatsu genuine parts)
Power train case

Final drive case
Power train oil TO30 (Komatsu genuine parts)
Damper case
Idler (each)
Hydraulic system Power train 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 inter-
val.
● Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of problems with machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
● Never mix oils of different grades or brands.
● Always add the specified amount of oil.

Having too much oil or too little oil are both causes of problems.
● If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
● When changing the oil, always replace the related filters at the same time.
● We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
● When using commercially available oil, it may be necessary to reduce the oil change interval.
We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the
oil.
4-5
OUTLINE 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 -15ºC
(5ºF)), so 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.
BIO-FUEL
The biofuel is a fuel that is formed in a transesterification reaction of vegetable oil, animal fat, and edible oil. The
ASTM D975 diesel fuel can contain 5 % or less of biofuel.
Use the biofuel conforming to ASTM D7467 if its mixing ratio is between 6% to 20%.
The EN590 diesel fuel can contain 7 % or less of biofuel.
When you use 100% biofuel for mixing, it needs to conform to ASTM D6751 or EN14214.
In the United States, purchase the biofuel from the dealer certified by BQ-9000.
In the EU, purchase the biofuel from the member companies of European Biodiesel Board (EBB).
In other countries or regions, purchase the biofuel from the dealer that guarantees the same quality as BQ-9000
or EBB.
4-6
NOTICE
When you use biofuel other than the preceding diesel fuel and its mixing ratio is up to 20 %, obey the
precautions that follow.
• It is necessary to consult with the local regulatory authorities of engine exhaust gas regulation
whether the biofuel can be used or not.
• The fuel can possibly leak because of the deterioration of rubber material of the fuel hose.
Replace it with the fuel hose applicable for biofuel. Consult your Komatsu distributor for replace-
ment of the fuel hose.
• Biofuel cannot be stored for a long time because it is easy to deteriorate and change in quality.
Use the fuel in the storage tank or the fuel tank of the machine within 6 months.
If the deteriorated and altered biofuel is used, it can cause bad effects on the engine parts.
When you store the machine which uses the diesel fuel mixed with the biofuel for more than 3
months, do the procedure that follows.
• Replace it with pure diesel fuel or the new diesel fuel mixed with the biofuel at the lowest possi-
ble mixing ratio.
• After you change the fuel, run the engine for a minimum of 30 minutes before you store the ma-
chine.
• Because the biofuel dissolves the materials sticking to the fuel tank and fuel line, the fuel filter can
be clogged with them.
When you change the diesel fuel to the biofuel, replace the fuel main filter cartridge and fuel prefil-
ter cartridge with new ones. When you replace the fuel main filter cartridge and fuel prefilter car-
tridge, make the replacement interval half the normal time until the second replacement after you
change the diesel fuel to the biofuel.
• Because the biofuel absorbs moisture easily, it can possibly cause a growth of microorganism.
When the microorganism grows in the biofuel, it can cause corrosion of the fuel system and the
clogging of the fuel filter.
Drain the water from the fuel tank before you start the operation.
When you complete the operation, fill the fuel tank to reduce the air layer.
• If the biofuel is used in the conditions of the specific operation, the fuel can possibly get mixed into
the engine oil.
The fuel level in the engine oil must not exceed 5 %. Deteriorated engine oil can cause adverse ef-
fects on the engine parts such as a reduction of lubricating function. It is recommended to take a
sample of the oil on a periodic basis.
• The characteristics of the biofuel change when outside air temperature is low. The fuel filter can be
clogged and the fuel inside the fuel tank can be solidified. Store the biofuel in the warm building or
in the storage tank.
The energy density of the biofuel becomes lower by 7 to 10% with that of the diesel fuel. Fuel consumption and
output can possibly be lowered when the mixing ratio is high.
Fuel hose quality can change as time passes due to the influence of material of bio when using BDF that mixing
ratio is over 20 % and they are likely to wear out or deteriorate.
Strongly recommend to replace Fuel hose every 2 years or every 4000 hours, whichever comes sooner.
PARAFFIN-BASED FUEL
The paraffin-based fuel is generated by natural gas, coal, vegetable oil, and animal and plant fat, and its main
constituent is paraffin.
The paraffin-based fuel has almost the same characteristics as the diesel fuel.
Vegetable oil and fat-derived fuel are called renewable diesel (RD) and hydrogenated vegetable oil (HVO).
The fuel synthesized from natural gas is called gas-to-liquid (GTL).
NOTICE
Use the paraffin-based fuel which agrees with EN15940:2016 and ASTM D975.
As long as the fuel agrees with EN15940:2016 and ASTM D975, its mixing ratio can be up to 100%.
The energy density of the paraffin-based fuel becomes lower up to 10% with that of the diesel fuel. Thus, fuel
consumption and output can possibly be lowered.
4-6-1
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.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
● When diluting the antifreeze coolant, use distilled water or tap water (soft water).
Natural water, such as a river water or well water (hard water), contains large amounts of minerals (calcium,
magnesium, etc.), and this makes it easier for scale to form inside the engine or radiator. Once scale is depos-
ited inside the engine or radiator, it is extremely difficult to remove. It also causes overheating due to poor heat
exchange, so when you dilute the coolant, we recommend that you use water with an overall hardness of less
than 100 PPM.
● When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
● Antifreeze coolant is flammable, so be sure to keep it away from flame.
● The ratio of Supercoolant (AF-NAC) to water differs according to the ambient temperature.
For details of the ratio when mixing, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-23)".
Supercoolant (AF-NAC) may be supplied already mixed. In such cases, never dilute with water.
● If the engine overheats, wait for the engine to cool before adding coolant.
● If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air
entering the coolant.
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
anual.
● 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.
4-6-2
● Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would
cause wear of the rotating parts.
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA,
the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and
other abnormalities.
We strongly recommend you to use this service. The oil analysis is carried out at actual cost, so the cost is low,
and the results of the analysis are reported together with recommendations which will reduce repair costs and
machine downtime.
KOWA ANALYSIS ITEMS

● Measurement of density of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of iron, copper, and other metal wear
particles in the oil.
● Measurement of quantity of particles

This uses a particle quantifier index measurement machine
to measure the quantity of iron particles of 5µ 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.
4-7
STORING OIL AND FUEL

● Keep indoors to prevent any water, dirt, or other impurities from getting in.
● When keeping drum cans for a long period, put the drum on its side so that the filler port of the drums is at the
side to prevent moisture from being sucked in.
If drums have to be stored outside, cover them with a waterproof sheet or take other measures to protect
them.
● To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use
the oldest oil or fuel first).
FILTERS
● Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
● Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
● When replacing oil filters, check if any metal particles are affixed to the old filter. If any metal particles are
found, please contact your Komatsu distributor.
● Do not open packs of spare filters until just before they are to be used.
● Always use Komatsu genuine filters.
BATTERY TERMINAL
● Make sure that the battery terminals have no looseness or corrosion.
● If there is looseness, make sure that there is no damage or corrosion, and retighten it.
● For the procedure to retighten and the torques, etc., see "REMOVE AND INSTALL BATTERY (PAGE 3-123)" .
● If there is corrosion, fully clean the rust on the battery and battery cable, and replace the battery terminals.
● When you replace the battery terminals, obey the instructions given in "PRECAUTIONS FOR MAINTENANCE
(PAGE 2-27)".
4-8
RELATING TO ELECTRIC SYSTEM

● It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged.
This will cause electrical leakage and may lead to malfunction of the machine. Do not wash the inside of the
operator's cab with water. When washing the machine, be careful not to let water get into the electrical compo-
nents.
● Service relating to the electric system is check of fan belt tension, check of damage or wear in the fan belt and
check of battery fluid level.
● Never install any electric components other than there specified by Komatsu.
● External electrical interference may cause malfunction of the control system controller, so before installing a
radio receiver or other wireless equipment, please contact your Komatsu distributor.
● Be careful to keep the electric system free of water when washing the machine or when it rains.
● When working at the seashore, carefully clean the electric system to prevent corrosion.
● When installing an operator's cab cooler or any other electrical equipment, connect it to an independent power
source connector. The optional power source must never be connected to the fuse, starting switch, or battery
relay.
4-9
WEAR PARTS MAINTENANCE
WEAR PARTS
Wear parts such as the filter element, air cleaner element etc. are to be replaced at the time of periodic mainte-
nance or before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
When changing parts, use Komatsu genuine parts of excellent quality.
When ordering parts, please check the part number in the parts book.
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)
07063-01054 Element - 1 Every 250 hours

Power train filter
(07000-72100) (O-ring) - (1) service
Fuel filter 600-311-8293 Cartridge - 1 Every 500 hours
Engine oil filter 600-211-1231 Cartridge - 1 service
Every 1000
Corrosion resistor 600-411-1151 Cartridge - 1
hours service
07063-01100 Element - 1
Hydraulic filter Every 2000
(07000-02140) (O-ring) - (1)
hours service
Hydraulic tank breather 20Y-60-21470 Element - 1
6125-81-7032 Element assembly - 1
Air cleaner Outer element -
600-181-4300 - 1
assembly
Air Fresh filter 14X-911-7750 Filter - 1

-
conditioner Recirc filter 14X-911-7741 Filter - 1
Electrical intake air heater 6150-11-4821 Gasket - 2 -
154-72-11151 Cutting edge 44.0 3
150-70-21356 End bit (left) 26.2 1
Tiltdozer 150-70-21346 End bit (right) 26.2 1 -
(02090-11270) (Bolt) - (30)
(02290-11219) (Nut) - (30)
154-70-11314 Cutting edge 52.9 3
150-70-21356 End bit (left) 26.2 1
Angle dozer 150-70-21346 End bit (right) 26.2 1 -
Blade (02090-11270) (Bolt) - (36)
(02290-11219) (Nut) - (36)
154-72-11151 Cutting edge 44.0 3
(02090-11270) (Bolt) - (18)
(02290-11219) (Nut) - (18)
Semi-U blade
175-71-22272 End bit (left) 39.0 1 -
(tilt dozer)
175-71-22282 End bit (right) 39.0 1
(02090-11495) (Bolt) - (14)
(02290-11422) (Nut) - (14)
NOTICE
When handling parts that weight more than 25kg, remember that they are heavy objects, and take the nec-
essary care.
4-10
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 0.5%, 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 0.5%, change the oil according to the following table.
Fuel sulfur content Engine oil change interval
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
4-11
RECOMMENDED FUEL, COOLANT, AND LUBRICANT MAINTENANCE
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO

AMBIENT TEMPERATURE
Ambient Temperature, degrees Celsius

Recommended
Reservoir Fluid Type -22 -4 14 32 50 68 86 104 122 F Komatsu Fluids
-30 -20 -10 0 10 20 30 40 50 C
Komatsu
SAE10W30DH
EO10W30DH
Komatsu
Engine oil pan Engine oil SAE15W40DH
EO15W40DH
Komatsu
SAE30DH
EO30DH
Damper case Power train oil

TO30 TO30
Idler (each) (Note. 1)
TO10 TO10
Power train case Power train oil
TO30 TO30
Final drive case

Power train oil TO30 TO30
(each)
Power train oil TO10 TO10
Hydraulic oil HO46-HM HO46-HM

Hydraulic system
Komatsu
SAE10W30DH
EO10W30DH
Engine oil
Komatsu
SAE15W40DH
EO15W40DH
Hyper grease
G2-T, G2-TE G2-T, G2-TE
(Note. 2)
Grease fitting
Lithium EP grease G2-LI G2-LI
Supercoolant
Cooling system AF-NAC (Note. 3) AF-NAC
AF-NAC
No.2-D ASTM No.2-D
Fuel tank Diesel fuel
No.1-D ASTM No.1-D
Cooling
Final
Engine oil Damper Idler Power Hydraulic system
drive case Fuel tank
pan case (each) train case system (incl.
(each)
sub-tank)
Specified Liter 44 1.7 0.15 68 27 95 58 410

capacity US gal 11.62 0.45 0.04 17.97 7.13 25.10 15.32 108.32
Refill Liter 38 1.7 0.15 48 27 55 — —

capacity US gal 10.04 0.45 0.04 12.68 7.13 14.53 — —
4-12
The ASTM D975 diesel fuel can contain 5 % or less of biofuel.

The EN590 diesel fuel can contain 7 % or less of biofuel.
NOTICE
When you use biofuel other than the preceding diesel fuel and its mixing ratio is up to 20 %, obey the precautions that follow.
It is necessary to consult with the local regulatory authorities of engine exhaust gas regulation whether the biofuel can be used
or not.
The fuel can possibly leak because of the deterioration of rubber material of the fuel hose.
Replace it with the fuel hose applicable for biofuel. Consult your Komatsu distributor for replacement of the fuel hose.
Biofuel cannot be stored for a long time because it is easy to deteriorate and change in quality.
Use the fuel in the storage tank or the fuel tank of the machine within 6 months.
If the deteriorated and altered biofuel is used, it can cause bad effects on the engine parts.
When you store the machine which uses the diesel fuel mixed with the biofuel for more than 3 months, do the procedure that
follows.
• Replace it with pure diesel fuel or the new diesel fuel mixed with the biofuel at the lowest possible mixing ratio.
• After you change the fuel, run the engine for a minimum of 30 minutes before you store the machine.
Because the biofuel dissolves the materials stuck to the fuel tank and fuel line, the fuel filter can be clogged with them.
When you change the diesel fuel to the biofuel, replace the fuel main filter cartridge and fuel prefilter cartridge with new ones.
When you replace the fuel main filter cartridge and fuel prefilter cartridge, make the replacement interval half the normal time
until the second replacement after you change the diesel fuel to the biofuel.
Because the biofuel absorbs moisture easily, it can possibly cause a growth of microorganism.
When the microorganism grows in the biofuel, it can cause corrosion of the fuel system and the clogging of the fuel filter.
Drain the water from the fuel tank before you start the operation.
When you complete the operation, fill the fuel tank to reduce the air layer.
If the biofuel is used in the conditions of the specific operation, the fuel can possibly get mixed into the engine oil.
The fuel level in the engine oil must not exceed 5 %. Deteriorated engine oil can cause adverse effects on the engine parts such
as a reduction of lubricating function. It is recommended to take a sample of the oil on a periodic basis.
The characteristics of the biofuel change when outside air temperature is low. The fuel filter can be clogged and the fuel inside
the fuel tank can be solidified. Store the biofuel in the warm building or in the storage tank.
NOTICE
Use the paraffin-based fuel which agrees with EN15940:2016 and ASTM D975.
As long as the fuel agrees with EN15940:2016 and ASTM D975, its mixing ratio can be up to 100 %.
4-12-1
RECOMMENDED FUEL, COOLANT, AND LUBRICANT MAINTENANCE
4-12-2
Note 1: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 2: 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 3: Supercoolant (AF-NAC)

1) Coolant has the important function of anticorrosion as well as antifreeze.
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.
2) For details of the ratio when diluting super coolant with water, see "CLEAN INSIDE OF COOLING SYS-
TEM (PAGE 4-23)".
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more
Supercoolant (AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F).
(never dilute with water)
3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Super-
coolant 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, or when checking the latest specifica-
tions, refer to the Komatsu web page or consult your Komatsu distributor.
4-13
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.
The tightening torque is determined by the width across the flats of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that
was replaced.
Tightening torque
Width
Thread across Target value Service limit
diameter flat b
a (mm) (mm) N•m kgf•m lbft N•m kgf•m lbft
6 10 13.2 1.35 9.8 11.8 - 14.7 1.2 - 1.5 8.7 - 10.8
8 13 31 3.2 23.1 27 - 34 2.8 - 3.5 20.3 - 25.3
10 17 66 6.7 48.5 59 - 74 6.0 - 7.5 43.4 - 54.2
12 19 113 11.5 83.2 98 - 123 10.0 - 12.5 72.3 - 90.4
14 22 177 18 130.2 157 - 196 16.0 - 20.0 115.7 - 144.7
16 24 279 28.5 206.1 245 - 309 25.0 - 31.5 180.8 - 227.8
18 27 382 39 282.1 343 - 425 35.0 - 43.5 253.2 - 314.6
20 30 549 56 405.0 490 - 608 50.0 - 62.0 361.7 - 448.4
22 32 745 76 549.7 662 - 829 67.5 - 84.5 488.2 - 611.2
24 36 927 94.5 683.5 824 - 1030 84.0 - 105.0 607.6 - 759.5
27 41 1320 135.0 976.5 1180 - 1470 120.0 - 150.0 868.0 - 1085.0
30 46 1720 175.0 1265.8 1520 - 1910 155.0 - 195.0 1121.1 - 1410.4
33 50 2210 225.0 1627.4 1960 - 2450 200.0 - 250.0 1446.6 - 1808.3
36 55 2750 280.0 2025.2 2450 - 3040 250.0 - 310.0 1808.3 - 2242.2
39 60 3280 335.0 2423.1 2890 - 3630 295.0 - 370.0 2133.7 - 2676.2
Apply the following table for Hydraulic Hose.

Tightening torque
Width
Thread across Target value Service limit
diameter flat b
a (mm) (mm) N•m kgf•m lbft N•m kgf•m lbft
14 19 29.4 3.0 21.7 27.5 - 39.2 2.8 - 4.0 20.3 - 28.9
18 24 78.5 8.0 57.3 58.8 - 98.1 6.0 - 10.0 43.4 - 72.3
22 27 117.7 12.0 86.8 88.3 - 137.3 9.0 - 14.0 65.1 - 101.3
24 32 147.1 15.0 108.5 117.7 - 176.5 12.0 - 18.0 86.8 - 130.2
30 36 215.7 22.0 159.1 176.5 - 245.2 18.0 - 25.0 130.2 - 180.8
33 41 255.0 26.0 188.1 215.7 - 284.4 22.0 - 29.0 159.1 - 209.8
4-14
MAINTENANCE DEFINED LIFE PARTS
DEFINED LIFE PARTS

For using the machine safely for a long period, always perform periodic inspection of the defined life parts that
have a particularly close relation to safety, such as hoses and the seat belt.
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. Check if there is any abnormality in wear or deterioration on them before work and at the regular
maintenance.
Replace immediately the hose if any defect is found by checking. If any of the hose clamps show deterioration
like deformation or cracking, replace the clamps at the same time as the hoses.
Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings,
gaskets, and other such parts at the same time.
Inspection/
No. Target Parts Q'ty Replacement Interval
1 Fuel hose (fuel tank - injection pump) 1
Every 2 years or
2 Fuel hose (injection pump - fuel filter) 2 every 4000 hours,
whichever comes
3 Fuel return hose (injection pump - fuel tank) 1
sooner.
4 Fuel return hose (injection nozzle - fuel tank) 1
5 Hose (power train strainer - power train pump) 1
6 Hose (power train pump - power train filter) 1
7 Hose (power train filter - transmission case) 1
8 Hose (transmission case - steering case) 1
9 Hose (power train lubrication pump - steering case) 1 Replace if any of the
damages were found
10 Hose (Scavenging pump - Steering case) 1 when the daily check
11 Hose (torque converter case - transmission oil cooler) 1 or periodical
maintenance.
12 Hose (transmission oil cooler - transmission case) 1
13 Brake pressure detection hose 2
14 Steering clutch pressure detection hose 2
15 Torque converter inlet post pressure detection hose 1
16 Torque converter outlet post pressure detection hose 1
17 Transmission modulation pressure detection hose 1

Every 3 years from
start of usage or 5
years after
18 Seat belt 1
manufacturing of seat
belt,whichever comes
sooner.
4-15
DEFINED LIFE PARTS MAINTENANCE
4-16
MAINTENANCE MAINTENANCE SCHEDURE CHART
MAINTENANCE SCHEDURE CHART

MAINTENANCE SCHEDURE CHART
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ............................................................................ 4-19
CLEAN INSIDE OF COOLING SYSTEM............................................................................................................ 4-23
CHECK TRACK TENSION ................................................................................................................................. 4-26
CHECK AND TIGHTEN TRACK SHOE BOLTS ................................................................................................. 4-27
CHECK ELECTRICAL INTAKE AIR HEATER.................................................................................................... 4-28
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES................................................................ 4-29
CLEAN, CHECK RADIATOR FINS..................................................................................................................... 4-30
CHECK, ADJUST AIR CONDITIONER .............................................................................................................. 4-31
GREASE DOOR HINGE ..................................................................................................................................... 4-32
CHECK DOOR LOCK STRIKER ........................................................................................................................ 4-32
REPLACE DOOR DAMPER ............................................................................................................................... 4-32
CHECK DOOR LATCH ....................................................................................................................................... 4-33
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ................................................................................. 4-34
REPLACE WIPER BLADE.................................................................................................................................. 4-35
CHECK IDLER OIL LEVEL, ADD OIL................................................................................................................. 4-36
ADJUST IDLER CLEARANCE............................................................................................................................ 4-37
PROCEDURE FOR BLEEDING AIR OF HYDRAULIC SYSTEM....................................................................... 4-37
ADJUSTING SHIMS, ADJUSTING TENSION AT WORK EQUIPMENT LINKS ................................................ 4-38
CLEAN INSIDE OF TRUNNION COVER ......................................................................................................... 4-44-1

DRAIN WATER, SEDIMENT FROM FUEL TANK .............................................................................................. 4-46

LUBRICATING .................................................................................................................................................... 4-47
GREASE EQUALIZER BAR SIDE PIN ............................................................................................................... 4-48
GREASE EQUALIZER BAR CENTER PIN......................................................................................................... 4-48
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...................................................................................... 4-49
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ....................................................................................... 4-50
CHECK LEVEL OF BATTERY ELECTROLYTE................................................................................................. 4-51
DRAIN WATER, SEDIMENT FROM FUEL FILTER ........................................................................................... 4-52
CHECK FAN BELT TENSION, ADJUST ............................................................................................................ 4-52
CHECK, CLEAN FUEL STRAINER .................................................................................................................... 4-53
REPLACE POWER TRAIN OIL FILTER ELEMENT........................................................................................... 4-53
CHECK BRAKE PERFORMANCE ..................................................................................................................... 4-55
4-17
MAINTENANCE SCHEDURE CHART MAINTENANCE
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) ............................................................... 4-56

REPLACE FUEL FILTER CARTRIDGE.............................................................................................................. 4-57
METHOD OF USING AUTOMATIC AIR BLEED MECHANISM ......................................................................... 4-58
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................................ 4-59

CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING
PUMP STRAINER) ............................................................................................................................................. 4-60
CHECK OIL LEVEL IN DAMPER CASE, ADD AND CHANGE OIL ................................................................... 4-62
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................................... 4-63
CLEAN BREATHER............................................................................................................................................ 4-63
GREASE UNIVERSAL JOINT ............................................................................................................................ 4-65
REPLACE CORROSION RESISTOR CARTRIDGE........................................................................................... 4-66
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER .............................................................................. 4-66
CHECK PLAY OF TURBOCHARGER ROTOR .................................................................................................. 4-66
CHECK FOR LOOSE ROPS MOUNT BOLTS ................................................................................................... 4-66

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMET
AND CLEAN SUCTION STRAINER ................................................................................................................... 4-67
REPLACE HYDRAULIC TANK BREATHER ELEMENT .................................................................................... 4-69
CLEAN ENGINE BREATHER ELEMENT ........................................................................................................... 4-70
CHANGE OIL IN DAMPER CASE ...................................................................................................................... 4-70
CLEAN, CHECK TURBOCHARGER .................................................................................................................. 4-71
CHECK VIBRATION DAMPER........................................................................................................................... 4-71
CHECK ALTERNATOR, STARTING MOTOR .................................................................................................... 4-71
CHECK ENGINE VALVE CLEARANCE, ADJUST ............................................................................................. 4-71

CHECK WATER PUMP ...................................................................................................................................... 4-72
4-18
MAINTENANCE SERVICE PROCEDURE
SERVICE PROCEDURE
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
WARNING
● If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the
engine and the engine will suffer damage. Always stop the engine before carrying out these opera-
tions.
● When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use safety glasses, dust mask, and other protective equipment.
CHECKING
Whenrver the red piston in dust indicator (1) appears,clean the
air cleaner element.
NOTICE
Do not clean the air cleaner element before the dust indi-
cator becomes red. If the element is cleaned frequently
before the dust indicator becomes red, the performance of
the air cleaner is not used perfectly and the cleaning effect
is lowered. In addition, dust sticking to the element falls
into the inner element each time the element is cleaned.
4-19
SERVICE PROCEDURE MAINTENANCE
CLEANING OUTER ELEMENT

1. Open the left engine side cover.
2. Loosen bolt (2), remove cover (3).
3. Remove the wing nut (4) and the seal washer (5), and
take out the outer element (6).
4. Clean the air cleaner housing interior and the cover.
5. Direct dry compressed air (less than 0.69MPa (7kg/cm2

,99.4 PSI)) to the outer element from inside along its
folds, then direct it from outside along its folds and again
from inside.
1) Remove one seal from the element whenever the

element has been cleaned.
2) Replace the outer element if it has been cleaned 6

times repeatedly or used throughout a year. Replace
the inner element at the same time.
3) Replace both inner and outer elements when the dust indicator red piston appears soon after installing
the cleaned outer element even though it has not been cleaned 6 times.
4) Check inner element mounting nuts (8) for looseness and, if necessary, retighten.
6. If small holes or thinner parts are found on the element

when it is checked by shining a light through it after
cleaning, replace the element.
NOTICE
When cleaning the element, do not hit or beat it against
anything.
Do not use an element whose folds, gasket or seal are
damaged.
4-20
7. Install the cleaned element and secure it with wing nut (5)
and seal washer (4).
If seal washer (4) or threads of wing nut (5) are damaged
or have any defect, replace with new one.
8. Remove the evacuator valve (11), clean with dry compressed air and then reinstall it.
9. Install the cover (3).
10. Press the button of dust indicator (1) to return the red pis-
ton to its original position.
11. Close the left engine side cover.
REPLACING ELEMENT
1. Open the left engine side cover.
2. Loosen bolt (2), remove cover (3).
3. Remove the wing nut (4) and the seal washer (5), and
take out the outer element (6).
4. Remove the snap ring (7), nut (8) and washer (9), and
then take out the inner element (10).
5. To prevent dust from getting in, use a clean cloth or tape

to cover the air connector (outlet side).
6. Clean the air cleaner housing interior, then remove the

cover installed in Step 5.
7. Fit a new inner element (10) to the air connector and

tighten with nut (8) and washer (9).
NOTICE
● The inner element (10) must not be cleaned and used
again.
When replacing the outer element (6), replace the inner
element (10) at the same time.
● The nut (8), washer (9), snap ring (7), wing nut (4) and
seal washer (5) must not be used again. replace them
with new ones.
8. Install the snap ring (7).
4-21
9. Install a new outer element (6) and secure it with the wing nut (4) and seal washer (5).
10. Remove the evacuator valve (11), clean with dry compressed air and then reinstall it.
11. Install the cover (3).
12. Press the button of dust indicator (1) to return the red pis-
ton to its original position.
13. Close the left engine side cover.
4-22
CLEAN INSIDE OF COOLING SYSTEM
WARNING
● Just after the engine is stopped, the coolant is still hot and the internal pressure in the radiator is still
high. If the radiator cap is removed under this condition, you may scald yourself. Accordingly, wait
until the temperature goes down, then loosen the cap slowly to release the pressure.
● Start the engine to clean the cooling system. When standing up from the operator's seat or leaving the
machine, set the work equipment lock lever and brake lock lever in the LOCK positions.
● For the starting method of the engine, see "CHECK BEFORE STARTING ENGINE, ADJUST (PAGE 3-
48)" and "STARTING ENGINE (PAGE 3-66)" in OPERATION in the section of operation.
● Never go under the machine body while the engine is running. It is very dangerous since the machine
may move suddenly.
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the
table below.
Interval of cleaning inside of cooling

Antifreeze coolant Replacing corrosion resistor
system and changing antifreeze coolant
Komatsu supercoolant Every two years or every 4000 hours

(AF-NAC) whichever comes first Every 1000 hours and when
cleaning the inside of the cooling
Permanent type antifreeze Every year (autumn) or every 2000 system and when changing coolant.
(All-season type, *) hours whichever comes first.
*: Permanent type antifreeze shall meet the requirements of ASTM D3306-03.
Stop the machine on level ground when cleaning or changing the coolant.
The coolant has the important function of preventing corrosion as well as preventing freezing.
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.
To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
4-23
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mix-
ing table given below.
It is actually better to estimate a temperature about 10ºC (18ºF) lower when deciding the mixing ratio.
The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (anti-
freeze/total amount of coolant x 100).
The freezing temperature of undiluted antifreeze is -15ºC (5ºF). Do not store undiluted antifreeze at a temperature
of below -15ºC (5ºF).
Mixing rate of water and antifreeze
Min. °C -10 -15 -20 -25 -30

atmospheric
temperature °F 14 5 -4 -13 -22
Amount of liters 17.4 20.9 23.8 26.7 29.0

antifreeze US gal 4.60 5.52 6.29 7.05 7.66
Amount of liters 40.6 37.1 34.2 31.3 29.0

water US gal 10.72 9.80 9.03 8.27 7.66
Ratio % 30 36 41 46 50
WARNING
Antifreeze is flammable, so keep it away from flame.
Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on
you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
Use antifreeze and appropriate water for diluting (for details, see "COOLANT AND WATER FOR DILUTION
(PAGE 4-6)")
We recommend use of an antifreeze density gauge to control the mixing proportions.
Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant.
Prepare a hose to supply antifreeze coolant and water.
1. Stop the engine and tighten 2 valves of the corrosion

resistor.
2. Turn radiator cap (1) slowly until it hits the stopper and by
so doing, relieving the internal pressure.
3. Turn radiator cap (1) until it hits the next stopper, while
depressing it. Keep turning the radiator cap (1) until it hits
the last stopper.
4. Place a container to receive the antifreeze solution under

drain valve (2) on the underside of the radiator and drain
valve (3) on the side of the cylinder block.
Open drain valve (2) and remove drain valve (3) to drain
the antifreeze solution.
5. After draining the antifreeze solution, close drain valve (2), (3), then fill with clean water. After the radiator is
filled with water, start and run the engine at low idling speed. After the water temperature rises above 90ºC
(194ºF), run the engine for about 10 minutes.
4-24
6. Stop the engine and open drain valve (2), (3) 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. Replace the corrosion resistor, then open 2 valves.

For details of the procedure for replacing the corrosion resistor, see "REPLACE CORROSION RESISTOR
CARTRIDGE (PAGE 4-66)".
9. Close drain valve (2), (3).
10. Add coolant mixed with antifreeze until it overflows from the water filler.
Decide the proportions of antifreeze and water according to the table for the mixing rate of water and anti-
freeze.
11. To remove air in the cooling system, run the engine for 5 minutes at low idle, then for 5 minutes at high idle.
(While doing this, leave the radiator cap removed.)
12. Drain the coolant from sub-tank (4), clean the inside of the sub-tank, then add water until the coolant level is
between the FULL and LOW marks.
13. Stop the engine, wait for approx. 3 minutes, then add coolant until the coolant level is near the coolant filler
port, and tighten the cap. Check the coolant level and add coolant if necessary.
14. Drain the coolant inside sub-tank (4), clean the inside of
the sub-tank, then fill again with coolant to a point mid-
way between the FULL and LOW marks.
15. Stop the engine and tighten the cap. Check the coolant
level and add water if necessary.
4-25
CHECK TRACK TENSION

The wear of pins and bushings on the undercarriage will vary with the working conditions and types of soil. It is
thus necessary to continually inspect the track tension so as to maintain the standard tension.
Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track
becomes clogged with mud, measure with the track clogged with mud).
INSPECTION
Stop the machine on level ground (stop with the transmission in
FORWARD without applying the brake). Then place a straight
bar on the track shoes between the carrier roller and the idler
as shown in the figure, and measure the clearance between
the bar and the grouser at the midpoint. If the clearance (a) is
20 to 30mm (0.79 to 1.18in), 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 lubricator (1) under pres-
sure can penetrate the body causing injury or death.
For this reason, do not loosen lubricator (1) more than

one turn. Do not loosen any part other than lubricator (1).
Furthermore, do not bring your face in front of the grease
fitting.
If the track tension is not relieved by this procedure,

please contact your Komatsu distributor.
WHEN INCREASING TENSION

Prepare a grease gun.
1. Pump in grease through the grease fitting (2) with a

grease pump.
2. To check that the correct tension has been achieved,

move the machine backwards and forwards.
3. Check the track tension again, and if the tension is not

correct, adjust it again.
4-26
4. Continue to pump in grease until S becomes 0mm. 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.
WHEN LOOSENING TENSION
WARNING
It is extremely dangerous to release the grease by any
method except the procedure given below. If the track ten-
sion is not relieved by this procedure, please contact your
1. Loosen lubricator (1) gradually to release the grease.
2. Turn lubricator (1) a maximum of one turn.
3. If the grease does not come out smoothly, move the machine backwards and forwards a short distance.
4. Tighten lubricator (1).
5. To check that the correct tension has been achieved, move the machine backwards and forwards.
6. Check the track tension again, and if the tension is not correct, adjust it again.
CHECK AND TIGHTEN TRACK SHOE BOLTS

If the machine is used with track shoe bolts (1) loose, they will
break, so tighten any loose bolts immediately.
METHOD OF TIGHTENING (TRACK SHOE BOLTS)

1. Torque the track shoe bolts to 294 ± 29 N•m (30 ± 3 kgf•m, 217 ± 21.7 lbft). Then ensure the nut and shoe
are in close contact with the link contact surface.
2. After checking, tighten a further 120º ± 10º. (120 degrees is two flats on the nut)
4-27
METHOD OF TIGHTENING (MASTER CONNECTING BOLT)

1. Torque the track shoe bolts to 294 ± 29 N•m (30 ± 3 kgf•m, 217 ± 21.7 lbft). Then ensure the nut and shoe
are in close contact with the link contact surface.
2. After checking, tighten a further 180º ± 10º. (120 degrees is two flats on the nut)
ORDER FOR TIGHTENING

Tighten the bolts in the order shown in the diagram on the right.
CHECK ELECTRICAL INTAKE AIR HEATER

Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air
heater repaired or checked for dirt or disconnections.
4-28
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 end bits and cutting edges before it is worn out to the blade end.
1. Raise the blade to a proper height and apply a block to the frame so as to prevent fall of the blade.
2. Operate the work equipment lock lever to the LOCK position.
3. Measure the wear of the end bit and cutting edge in accordance with the wear standards given below.
Wear standards
Unit: mm (in)
Item Judgement standard
Work Standard Repair

No. Measurement point
equipment dimension limit
Height of outside of A,C 292 (11.5) 254 (10.0)

1
end bit B 315 (12.4) 254 (10.0)
A,C 435 (17.1) 410 (16.2)
2 Width of end bit
B 540 (21.3) 515 (20.3)
Height of inside of end

3 A,B,C 254 (10.0) 237 (9.3)
bit
Height of cutting edge

(from center of bolt
4 A,B,C 127 (5.0) 103 (4.1)
mounting hole to end
face)
The symbols in the work equipment column have the following meaning.
A: Powertilt dozer
B: Semi-U blade
C: Angledozer
REMARK
● If the cutting edge and the end bit on both sides are worn out, replace with new one.
● If it has been worn out up to the fitting surface, repair the fitting surface and then reverse or replace.
4. Remove the cutting edge and the end bit and clean the mounting surface.
4-29
5. Reverse or replace the cutting edge and the end bit when worn out.
1) Remove nut (1) and bolt (2), then replace or reverse

the cutting edge and the end bit.
2) Install the cutting edge to the blade and tighten the

bolt temporarily. Press the blade against the ground
to eliminate the play of bolt (2), then tighten the bolt
to the specified torque.
Nut tightening torque:
Powertilt dozer: 461 ± 69 N•m (47 ± 7 kgf•m, 340 ± 51 lbft)
Semi-U dozer (cutting edge): 461 ± 69 N•m (47 ± 7 kgf•m, 340 ± 51 lbft)
Semi-U dozer (end bit): 745 ± 108 N•m (76 ± 11 kgf•m, 549.7 ± 79.6 lbft)
If bolt (2) and nut (1) are damaged, replace them with new ones at the same time.
6. After several hours of running, retighten the nuts.
CLEAN, CHECK RADIATOR FINS

1. Loosen 4 bolts (1), then remove the radiator mask.
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 rubber hose. If the hose is found to have cracks to be hardened by ageing, replace such hose with new
one. Further, loosen hose clamp should also be checked.
3. Install the radiator mask with 4 bolts (1).
4-30
CHECK, ADJUST AIR CONDITIONER

CHECKING TENSION OF COMPRESSOR BELT

If the belt is loose, it will slip and the cooling effect will be
reduced. From time to time, press a point midway between the
drive pulley and compressor pulley with your finger (approx.
98N (10kgf,22.05 lb)) and check that the tension is 15 to 18mm
(0.59 to 0.71in). When the belt is new, there will be initial elon-
gation, so always adjust again after 2 or 3 days.
CHECK LEVEL OF REFRIGERANT (GAS)
WARNING
If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or
frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.
Do not bring any flame close to any point where the refrigerant gas is leaking.
If the level of the refrigerant (gas) is low, the cooling effect will
be reduced. Run the engine at high idling, and check the flow
of the refrigerant in the refrigerant circuit through the sight
glass of the receiver when the cooler is running at high speed.
● No bubbles in refrigerant flow: Suitable
● Some bubbles in flow (bubbles pass continuously): Lack of

refrigerant
● Colorless, transparent: No refrigerant
REMARK
● When there are bubbles, the refrigerant gas level is low, so contact your refrigerant dealer to have refrigerant
added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
● New Freon R134a is used as the refrigerant.
4-31
OPERATING THE AIR CONDITIONER OFF-SEASON

Even during the off-season, run the compressor at low speed for 3 to 5 minutes once a month to prevent the loss
of the oil film at the lubricated parts of the compressor.
GREASE 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 LOCK STRIKER

If the wear of the doors lock striker exceeds 0.5mm (0.02in),

replace the striker. If it is used at it is, the play will increase and
this may result in breakage of the hinge or door lock.
REPLACE DOOR DAMPER

If the depth of the door damper rubber groove is less than 2mm
(0.08in), replace the damper.
There are four dampers each at the top and bottom on the left
and right doors.
4-32
CHECK DOOR LATCH

1. Hold the door open and check that there is still grease
inside the latch.
If the amount of grease is low or there is no more grease,
coat the inside of the latch with grease from portion (1).
REMARK
If there is no more grease inside the latch, the movement will
become poor because of dust inside the latch, and the handle
may be stiff when opening the door.
4-33
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID

If there is air in the window washer fluid, check the level and
add fluid.
Open the engine side cover on the left side, check the level of
the fluid in window washer tank (1), and if it is low, add automo-
bile window washer fluid.
When adding fluid, be careful not to let any dust get in.
PROPORTION FOR MIXING WASHER FLUID WITH WATER

The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following
proportions before adding.
Area, season Proportions Freezing temperature
Normal Washer fluid 1/3 : water 2/3 -10ºC (14ºF)
Winter in cold area Washer fluid 1/2 : water 1/2 -20ºC (-4ºF)
Winter in extremely cold area Pure washer fluid -30ºC (-22ºF)
There are two types depending on the freezing temperature:

-10ºC (14ºF) (general use) and -30ºC (-22ºF) (cold area use), so select according to the area and season.
4-34
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.
DOOR WIPER
1. It is hooked at portion (A), so move the blade in the direc-
tion of the arrow to remove it.
2. Install the new blade and hook it securely.
4-35
CHECK IDLER OIL LEVEL, ADD OIL
WARNING
If the oil level in the idler is low, new oil must be added, and the machine body must be inclined in this
case. Since this work is dangerous, ask your Komatsu distributor.
If the oil level in the idler is low, noise will be generated and there will be seizure, so check the oil level and add oil
as follows.
INSPECTION
1. Remove bolt (1), then remove guide plate (2) and shim
(3).
REMARK
When removing shim (3) keep it in a safe place and be careful
not to lose it.
2. Loosen plug (4) slowly. If oil oozes through the threads at

this time, the quantity of oil is sufficient. Tighten plug (4).
3. If any oil does not flow out when plug (4) is removed, the
quantity of oil is insufficient. In this case, ask your
Komatsu distributor for repair.
4. Install guide plate (2) and shim (3) with bolt (1).
REMARK
When installing guide plate (2), install the same number and
thickness of shim (3) as was removed in Step 1.
The optimum clearance may be obtained, if the adjustment is

made at the same time. For details of adjusting the shim thick-
ness, see "ADJUST IDLER CLEARANCE (PAGE 4-37)".
4-36
ADJUST IDLER CLEARANCE

Since the idlers are forced to move forward and backward by an external force guide plates will be worn out. Wear
of these plates will cause the vibration of idlers from side to side or inclination of the idlers, and running off of track
links from the idlers or unevenly worn idler and links may result.
Therefore, adjust the idlers according to the following procedure.
ADJUSTMENT
1. Move the machine by 1 to 2 m (3 ft 3 in to 6 ft 7 in) on a
level place, then measure clearance A between the track
frame and guide plate (at four places of both sides,
inside, and outside).
2. If the clearance A exceeds 4.0 mm (0.16 in), loosen bolt

(1), and pull out the shim to adjust the clearance at one
end to 0.5 to 1.0 mm (0.02 to 0.04 in).
Thickness of one shim is 1.0 mm (0.04 in).
PROCEDURE FOR BLEEDING AIR OF HYDRAULIC SYSTEM

See "STARTING ENGINE (PAGE 3-66)".
Since the engine must be started and the blade must be operated, see OPERATION.
NOTICE
If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air
inside the cylinder may cause damage to the piston packing.
1. Bleed air from head end of right pitch cylinder (Powertilt, Power pitch dozer only)
Bleeding air from the hydraulic system is required when removing and installing the work equipment or when
making the repairs.
1) Bring the blade to the RAISE position and run the engine under no load at low range.
2) Bleeding air in the tilt hydraulic circuit by repeating left and right tilt operation five to ten times.
3) Bleeding air from the bottom of RH cylinder by operating the blade to pitch forward and backward 5 to
10 times repeatedly.
4) Bleeding air from the RH pitch cylinder by repeating the following operation 5 to 10 times. Forward pitch
- Left tilt - Right tilt - Backward pitch.
2. Bleeding air from cylinders
1) Run the engine at low idling, and extend and retract each cylinder 4 to 5 times. Do not operate the cylin-
der to the end of its stroke. (Stop at a point approx. 100 mm before the end of the stroke.)
2) Next, operate each cylinder 3 to 4 times to the end of its stroke.
3) Finally, operate each cylinder 4 to 5 times to the end of its stroke to completely remove the air.
4-37
ADJUSTING SHIMS, ADJUSTING TENSION AT WORK EQUIPMENT LINKS

● When assembling the work equipment, carry out adjustment as follows.
● Check the play of the links periodically and carry out adjustment.
● When disassembling the machine for transportation, be careful not to lose the shims.
NEED FOR ADJUSTING WORK EQUIPMENT LINKS
CAUTION
If the clearances at each ball joint of the work equipment and the tension of the center brace are not
adjusted properly, it will lead to problems.
It is necessary to carry out adjustment properly regardless of whether the machine is new and regardless
of the number of years that it has been used.
Problems that occur when adjustment is not correct
Location Condition Problems that appear
● Work equipment play becomes excessive and performance deterio-

rates
Ball joint portion Excessive play
● Sand or dust enters through gap and causes wear
(portion A in diagram ● Impact load at joints increases and durability is reduced
below)
● Ball cannot rotate, excessive bending stress is generated, and
No play
cracks or damage occur
● Work equipment play becomes excessive and performance deterio-
rates
Insufficient ten-
Center brace ● Sand or dust enters bushing at blade connection and causes wear
sion
(portion B in diagram ● Shaking to side increases, lift cylinder hose contacts bodywork and
below) frame contacts track
Excessive ten- ● Excessive bending tension is generated, and cracks or damage
sion occur
● Power tiltdozer
● Semi U-dozer
● Angledozer
(There is no portion B on the angledozer)
4-38
LOCATIONS FOR ADJUSTMENT AND NEED FOR ADJUSTMENT
WARNING
It is dangerous if the work equipment moves by mistake when it is being adjusted. Move the machine to a
horizontal place, stop the machine, and set the work equipment in a stable condition. Then stop the
engine and set the work equipment lock lever securely to the LOCK position.
● Power tiltdozer
● Semi U-dozer
● Angledozer
1. Adjust the play of each link ball joint at positions (1) to (4).
(1) Tilt brace, tilt cylinder head
(2) Lift cylinder head
(3) Center brace
(4) Trunnion
2. Adjust the tension of center brace (5).
REMARK
For details of the procedure for adjusting each location, see the following items.
"ADJUSTING SHIMS AT TILT BRACE, TILT CYLINDER HEAD (PAGE 4-40)"
"ADJUSTING SHIMS AT LIFT CYLINDER HEAD (PAGE 4-41)"
"ADJUSTING SHIMS AT CENTER BRACE (PAGE 4-42)"
"ADJUSTING SHIMS AT TRUNNION (PAGE 4-43)"
"ADJUSTING TENSION OF CENTER BRACE (PAGE 4-44)"
4-39
METHOD OF ADJUSTING EACH LOCATION
ADJUSTING SHIMS AT TILT BRACE, TILT CYLINDER HEAD

● Correct value for play at ball joint: 0.2 - 0.7 mm
● Standard shim thickness: 5 mm
Use the following procedure to adjust the play at the ball joint to the correct value.
1. Remove bolts (1), then remove cap (2).
2. Wipe off the grease and dirt from the sliding surface of ball (3).
3. Remove all shims (4).
4. Install cap (2) and tighten bolts (1) temporarily.

Temporary tightening torque: 19.6 to 29.4 Nm (2 to 3 kgm, 14.5 to 21.7 lbft)
5. Measure clearance at portion A (top) and portion B (bottom) of ball joint, and calculate average clearance C
[C = (A + B) / 2].
Set so that the shim thickness is (C + 0.2) - (C + 0.7) mm.
The shim thickness can be set in units of 0.5 mm.
7. Install the thickness of shim measured in Step 5, then tighten cap (2) fully with bolts (1).
Tightening torque: 455 to 565 Nm (46.5 to 58 kgm, 336.3 to 419.5 lbft)
8. Before filling with grease, operate the work equipment and check that there is no abnormal noise or abnor-
mal play.
9. Pump in grease through the grease fitting of the ball joint.
10. After greasing, wipe off any old grease that was pushed out.
4-40
ADJUSTING SHIMS AT LIFT CYLINDER HEAD


[C = (A + B) / 2].
Tightening torque: 235 to 285 Nm (23.5 to 29.5 kgm, 170.0 to 213.4 lbft)
mal play.
4-41
ADJUSTING SHIMS AT CENTER BRACE


[C = (A + B) / 2].
Tightening torque: 455 to 565 Nm (46.5 to 58 kgm, 336.3 to 419.5 lbft)
mal play.
4-42
ADJUSTING SHIMS AT TRUNNION


Temporary tightening torque: 39.2 to 49 Nm (4 to 5 kgm, 28.9 to 36.2 lbft)
[C = (A + B) / 2].
The shim thickness can be set in units of 1 mm.
Tighten bolts (1) in turn at the top and bottom to reach the specified torque.
Tightening torque: 785 to 980 Nm (80 to 100 kgm, 578.6 to 723.3 lbft)
8. Operate the work equipment and check that there is no abnormal noise or abnormal play.
4-43
ADJUSTING TENSION OF CENTER BRACE

(Power tilt dozer)
(Semi-U dozer)
In case the work equipment assembly is disassembled for transportation and reassembled at a worksite, tension
of the center brace has to be adjusted anew. Otherwise the bushing at the connecting part of blade and straight
frame will likely slip off, allowing sand and dirt to enter the bushing, which eventually leads to premature wear or
damage of the bushing. Make this adjustment as follows:
WARNING
Except when operating the blade in Step 4, always lock the blade control lever securely with the work
equipment lock lever.
1. Adjust with shim (2) so that the play of ball joint (1) is 0.2
to 0.7 mm (0.008 to 0.028 in). For details of the method of
adjusting, see "ADJUSTING SHIMS AT CENTER
BRACE (PAGE 4-42)".
2. Loosen bolt (3).
3. Install the blade assembly.
4. Operate the blade control lever to float the blade.
5. Insert the bar in center brace hole (4) and turn the bar to the protruding side. At that time, adjust clearance
between the track shoe and frame (A) so that it is equal on the right and left sides.
Rotating torque: 24.5 to 49 Nm (2.5 to 5 kgm, 18.1 to 36.2 lbft) (Blade at FLOAT)
Standard distance between the joints (B) is as shown below.
992 mm (39.1 in)
6. Tighten bolt (3).

Tightening torque: 490.3 to 608 Nm (50 to 62 kgm, 361.7 to 448.4 lbft)
4-44
CLEAN INSIDE OF TRUNNION COVER

(Power tilt dozer)
(Semi-U dozer)
k WARNING
• It is dangerous if the work equipment moves by mistake during cleaning.
Stop the machine on a level ground, set the work equipment in a stable condition, and stop the en-
gine. Set the parking brake lever and work equipment lock lever to the LOCK position securely.
• If the compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by
use of it, there is a danger of personal injury. Wear the protective equipment such as protective eye-
glasses and dust mask.
NOTICE
If soils go inside the trunnion cover and load is applied to the hydraulic hose in the cover by the accu-
mulated soils, the hydraulic hose can be damaged.
Remove the soil and do the cleaning if soil is accumulated.
The position of the trunnion cover is different by the specifications.
Power tilt dozer, semi-U dozer: Right side of
work equipment (1 place)
1. Run the engine at low idling.

2. Lower the work equipment to the ground.
3. Stop the engine.
REMARK
Prevent the hydraulic relief at stroke end when you operate
the hydraulic cylinder.
If you stop the engine during the hydraulic relief at stroke
end, do not do the operation for 5 to 10 minutes.
4. Remove the 4 bolts (1), and remove the cover (2).
5. Remove soils accumulated inside the cover (2), and clean
it.
6. Remove soils accumulated inside the trunnion and around
the hose (3), and clean it.
7. After cleaning, make sure that the edge of the trunnion (4)
and hose (3) do not interfere with each other.
8. Install the cover (2) with the 4 bolts (1).
Tightening torque: 235 to 285Nm {23.5 to 29.5kgfm, 170 to
213lbft}
4-44-1
4-44-2

For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-50)" in the OPERATION section.
● Check coolant level, add water
● Checking with machine monitor
● Check speed range display lamp
● Check fuel level, add fuel
● 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 electric wiring
● Check that lamps light up
● Check horn sound
● Check back-up alarm sound
● Check for water and sediment in water separator, drain water (if equipped)
4-45
DRAIN WATER, SEDIMENT FROM FUEL TANK

1. Drain water and sediment before starting the machine.
2. Prepare a container to receive fuel to be drained.
3. Open drain valve (1) at the bottom of the tank to drain

sediment and water accumulated on the bottom, together
with fuel.
At this time, take care not pour fuel over yourself.
4. After clear fuel comes out, close drain valve (1).
4-46

Maintenance for every 50 hours service should be carried out at the same time.
LUBRICATING
1. Lower the blade to the ground, then stop the engine.
2. Using a grease pump, pump in grease through the grease fittings shown by arrows.
POWER TILTDOZER
(1) Lift cylinder support yoke (4 places)
(2) Lift cylinder support shaft (2 places)
(3) Lift cylinder ball joint (2 places)
(4) Tilt cylinder ball joint (1 place)
(5) Tilt brace ball joint (1 place)
(6) Brace ball joint (2 places)
(7) Tilt brace thread (1 place) (screw-adjustable)
4-47
ANGLEDOZER
(1) Lift cylinder support yoke (4 places)
(2) Lift cylinder support shaft (2 places)
(3) Lift cylinder ball joint (2 places)
(4) Tilt brace ball joint (2 places)
(5) Tilt brace thread (2 places)
GREASE EQUALIZER BAR SIDE PIN

Left and right 2 places each
1. Remove all dirt from the top of the track frame and cover
(1).
2. Clean the grease fitting indicated with the arrow, then

supply grease to that fitting with a grease pump.
REMARK
● Supply 3 shots of grease (Operate the grease pump lever
3 times) to each grease fitting, and check that grease is
newly discharged through the seal lip.
● If grease is not newly discharged through the lip, continue
supplying grease until it is discharged.
GREASE EQUALIZER BAR CENTER PIN

(1 place)
1. Open the left side cover of the machine body.
2. Clean the grease fitting indicated with the arrow, then

supply grease to that fitting with a grease pump.
4-48
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
WARNING
● The oil is at high temperature immediately after the machine has been operated. Wait for the oil to
cool down before starting the operation.
● If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.
1. Stop the machine so that drain plug (3) is directly at the

bottom.
2. Remove oil level plug (2) and check whether the final
drive case is filled with oil to lower edge of the plug hole.
3. If the oil level is too low, add engine oil through the oil
filler plug hole (1).
4. When oil starts to overflow from oil level plug (2), stop fill-
ing and install oil level plug (2) and oil filler plug (1).
4-49
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
WARNING
● The parts and oil are at high temperature after the engine is stopped, and may cause burns.Wait for
the temperature to go down before starting the work.
● When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
NOTICE
● Do not add oil if the level is above the H line. This will damage the hydraulic equipment and cause the
oil to spurt out.
● Always lock the cap with the key.
1. Lower the blade to the ground, stop the engine and wait
for about 5 minutes before checking oil level. If oil level is
between H and L in sight gauge (G).
2. If the level is below the L mark, add engine oil through oil
filler (F).
3. After adding oil, be sure to screw on the oil filler cap and
lock it with the key.
4-50
CHECK LEVEL OF BATTERY ELECTROLYTE
WARNING
● Since the battery produces combustible gas and can explode, do not bring fire near it.
● Battery fluid is a dangerous substance. Take care that it does not get in your eyes or on skin. If it
does, wash it away with a large quantity of water, then see a doctor.
● Do not use or charge the battery when its fluid level is below the LOWER LEVEL. If it is used or
charged as it is, it may explode. Be sure to check the battery fluid level periodically and add distilled
water to the UPPER LEVEL, as required.
● Do not use a direct air blow or dry cloth to clean the battery.
A wet cloth will prevent fire or explosion from static electricity.
Carry out this check before operating the machine.
1. Open the battery cover on the left side of the machine body.
2. Remove cap (1), and check if the battery electrolyte is up

to the UPPER LEVEL line. If the level is low, add distilled
water.
Do not add water above the UPPER LEVEL line. This
may cause the electrolyte to leak, which may cause fire
or injury.
If the electrolyte has spilled, add dilute sulfuric acid.
3. Clean the vents of the battery caps, then close the caps
securely.
Keep the top of the battery clean and wipe it with a wet
cloth.
NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent
the electrolyte from freezing.
4-51
DRAIN WATER, SEDIMENT FROM FUEL FILTER

1. Open the engine side cover on the left side of the
machine, remove drain plug (1) at the bottom of the fuel
filter, and drain the sediment and water together with fuel.
2. Tighten drain plug (1).
3. Loosen the knob of feed pump (2), and pump it up and

down approx. 50 - 60 times to bleed the air.
4. Push in the knob of feed pump (2) and tighten it.
CHECK FAN BELT TENSION, ADJUST
INSPECTION
The belt should normally deflect by 6 to 7mm (0.24 to 0.28in)
when pressed with the finger (with a force of approx. 59N
(6kgf)) at a point midway between the tension pulley and fan
pulley.
ADJUSTMENT
1. Loosen bolts and nuts (1), (2), (3).
2. Turn nut (4) clockwise, then move alternator (5) to adjust

the belt tension so that the deflection is approx. 10 mm
when pushed with a force of approx. 6 kg.
3. Tighten the bolts and nuts (1), (2), and (3) to fix alternator
(5) in position.
4-52
REMARK
● Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check
that the V-belt is not touching the bottom of the V-groove.
● If any pulley is defective, ask your Komatsu distributor to replace it.
● If any belt has stretched and there is no allowance for adjustment, or if there are cuts or cracks on any belt,
replace both belts at the same time.
● When adjusting the V-belt, do not push the tension pulley directly with a steel bar, etc., but put a wood piece,
etc. between the pulley and bar.
● After replacing the V-belt, operate for 1 hour, then check and adjust the belt tension again.
CHECK, CLEAN FUEL STRAINER

(If equipped)
1. Open the inspection cover at the bottom of the fuel tank.
2. Tighten the fuel supply valve, then remove the cap, and
clean the strainer and strainer case.
The strainer forms one unit with the cap.
3. After checking and cleaning the strainer, set it in the

case, then tighten the cap.
4. After installing, open the fuel supply valve.
REPLACE POWER TRAIN OIL FILTER ELEMENT
WARNING
The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool
down before starting the operation.
1. Remove top mounting bolts (2) of filter cover (1), then

use the bottom hinge as the fulcrum to open the cover to
the outside.
2. Remove seal (3) installed to the frame.
4-53
3. Remove mounting bolts (5) for filter (4), then remove

cover (6).
4. Remove the grommet under the fender, loosen drain plug

(P), and drain the oil from inside the filter case.
5. Take out element (7).
6. Clean the removed parts and the inside of the case, then
install a new element.
Use Komatsu genuine element.
7. Fix cover (6) with bolt (5) by making a horizontal hole of

the cover with filter case hole (A).
8. Install drain plug (P).
9. Loosen air vent plug (8) and start engine. Tighten the
plug when oil comes out.
10. Tighten framecover (1) and then bolt (2).
NOTICE
● When replacing seal (3), do it after closing cover (1).
● The seal will be damaged if the filter cover closes after
replacing it.
11. Replace frame seal (3).
4-54
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 gear shift lever in 1st under any circumstances. The machine will be damaged.
Before starting the engine, check that the area around the machine is safe, then do as follows.
2. Set work equipment lock lever (1) to the FREE position

then operate blade control lever (2) to raise the blade.
Leave the work equipment lock lever to the FREE posi-
tion.
3. Set brake lock lever (3) to the FREE position.
4. Depress brake pedal (4) and move steering, directional

and gear shift lever (5) in 2nd.
5. Operate fuel control lever (6) to raise the engine speed

gradually to full throttle.
6. Check that the machine does not move. This indicates

that brake performance is normal.
4-55
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.
In places where there is a lot of dust, clean the air filter once a week. In addition, clean the air conditioner air filter
at the same time when cleaning the engine air cleaner.
1. Loosen mounting bolts (1), pull up inspection cover (2) to

the rear, and remove it.
2. Remove inside cover (3), then remove FRESH filter (4).
3. Remove the filter box, then brush out the dirt accumu-
lated inside the box through the cleaning hole (5) in the
hood.
When doing this, be careful not to let any dirt or dust get
into the fresh air intake port (6) leading to the cab.
4. Open inspection cover (7) under the front panel, then pull
up RECIRC filter (8) and remove it.
5. Clean filters (4) and (8) with compressed air.

If the filters are stained with oil or extremely dirty, wash
them in neutral detergent.
After washing the filters, dry them up, then install them.
REMARK
If the filters cannot be cleaned with air or in water, replace them
with new ones.
4-56

Maintenance for every 50 and 250 hours service should be carried out at the same time.
REPLACE FUEL FILTER CARTRIDGE
WARNING
● Engine is at high temperature immediately after the machine has been operated. Wait for engine to
cool down before replacing the filter.
● Do not bring fire or sparks near the fuel.
Prepare a filter wrench and a container to catch the fuel.
1. Set the container to catch the fuel under the filter car-
tridge.
2. Using a filter wrench, turn filter cartridge (1) counterclock-

wise to remove it.
3. Clean the filter holder, fill a new filter cartridge with clean
fuel, coat the packing surface with engine oil, then install
it to the filter holder.
4. When installing, tighten until the packing surface contacts

the seal surface of the filter holder, then tighten it up 1/2
to 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 fil-
ter cartridge is too loose, fuel will also leak from the pack-
ing, so always tighten to the correct amount.
5. Loosen the knob of feed pump (2) and operate it 50 to 60 times up and down. This will bleed the air.
6. Push in the knob of feed pump (2) and tighten it.
7. After replacing the filter cartridge, start the engine and check that there is no leakage of fuel from the filter
seal surface. If there is any leakage of fuel, check the tightening of the filter cartridge. Whenever there is
leakage of fuel, follow Steps 1 and 2 to remove the filter cartridge, then check the packing surface for dam-
age or foreign material.
If any damage or foreign material is found in the packing, replace the packing with a new part, then repeat
Steps 3 - 6 to install the filter cartridge.
4-57
METHOD OF USING AUTOMATIC AIR BLEED MECHANISM

(If equipped)
WARNING
When cranking the engine, ensure no one is around the engine, as the engine may start.
NOTICE
When the engine has run out of fuel, turn the starting switch key to the START position and rotate the
starting motor for 15-20 seconds to crank the engine and bleed the air. Repeat this 2-3 times to bleed the
air completely. The time taken to bleed the air is shorter when the fuel tank is full. Do not rotate the starting
motor continuously for more than 20 seconds. Wait for 1-2 minutes before rotating it again.
It is possible to bleed the air from the fuel circuit simply by rotating the starting motor with the starting switch. Bleed
the air as follows;
1. After replacing the filter cartridge, check that the fuel con-
trol lever is at the low idling position.
2. Set the brake lock lever to the LOCK position.
3. Turn the starting switch key to the START position and

rotate the starting motor for 15-20 seconds to crank the
engine and bleed the air.
4-58
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CAR-
TRIDGE
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: 38 liters (10.04 US gal)

● Socket wrench, filter wrench.
1. Remove the cover on the bottom of the machine and set a container to catch the drained oil directly under
the drain plug.
2. Loosen drain plug (P) (with a slit) slowly to avoid getting

oil on yourself, and drain the oil.
3. Check the drained oil, and if there are excessive metal

particles or foreign material, please contact your
4. Install drain plug (P).
5. Using a filter wrench, turn filter cartridge (1) counterclock-

wise to remove it.
To prevent getting oil on yourself, do not carry out this
operation from immediately under the cartridge.
6. Clean the filter holder, fill the new filter cartridge with engine oil, coat the packing surface and thread with
engine oil (or coat it thinly with grease), then install the filter cartridge.
7. When installing the filter cartridge, bring the packing surface into contact with the filter holder, then tighten a
further 3/4 to1 turn.
8. After replacing the filter cartridge, add engine oil through oil filler port (F) so that the oil level is between the H
and L marks on dipstick (G).
9. Run the engine at idling for a short time, then stop the engine, and check that the oil level is between the H
and L marks on the dipstick. For details, see "CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL (PAGE 3-
54)".
4-59

Maintenance for every 50, 250 and 500 hours should be carried out at the same time.
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN

STRAINER, SCAVENGING PUMP STRAINER)
WARNING
● The undercover is heavy. Never try to open or close the cover when directly beneath it. When remov-
ing bolts (2), carry out the work from the rear below the cover so that you can easily get out of the
way.
1. Loosen drain plug (P) (with a slit), drain the oil, then
tighten drain plug (P) again.
Do not remove drain plug (P).
2. Remove the undercover from the rear bottom of the

machine body as follows.
1) Remove two bolts (1) from the front side of the

machine body.
2) Holding the cover, remove two bolts (2) from the rear
side of the machine body.
3) Lower and open the cover gradually.
4-60
3. Loosen mounting bolt (3) of the power train strainer, then

remove cover (4).
4. Take out spring (5), then take out strainer (6).
5. Remove all dirt from strainer (6), then wash in clean die-
sel oil or flushing oil. Clean the case interior and the
removed parts.
6. Loosen mounting bolt (7) of the scavenging pump

strainer, then remove cover (8).
7. Take out spring (9), then take out strainer (10).
8. Remove all dirt from strainer (10), then wash in clean die-
sel oil or flushing oil. Clean the case interior and the
removed parts.
9. Install the strainers to their original position.
10. After installing, replace the element in the power train oil
filter. For details, see "REPLACE POWER TRAIN OIL
FILTER ELEMENT (PAGE 4-53)".
11. Open cover at the right side of the machine.
12. Refill the specified quantity of engine oil through oil filler
(F).
13. Check that the oil is at the specified level. For details, see
"CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL
(PAGE 3-55)".
If the spring or strainer are damaged, replace them.
14. Close the cover at right side of machine.
4-61
CHECK OIL LEVEL IN DAMPER CASE, ADD AND CHANGE OIL
WARNING
● The oil is at high temperature immediately after the
machine has been operated. Wait for the oil to cool
down before starting the operation.
● The undercover is heavy. Never try to open or close

the cover when directly beneath it. When removing
bolts (2), carry out the work from the rear of the cover
so that you can easily get out of the way.
If the quantity of the oil in the damper is insufficient, the damper may be seized. Accordingly, check, and add or
replace the oil according to the following procedure.

machine body according to the following procedure.

machine body.
2. Remove oil level plug (3) and check the oil level. The
proper oil level is the bottom edge of the plug hole.
Tighten plug (3).
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.
3. If the oil level is below the bottom edge of the plug hole,
remove oil filler plug (4) and add new oil.
Add new engine oil until the oil level reaches the bottom
edge of oil level plug (3).
4. After adding the oil, tighten plugs (3) and (4).
4-62
CHANGE OIL IN FINAL DRIVE CASE
WARNING
● If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.
● Refill capacity:
(each) 27 liters (7.13 US gal)
1. Stop the machine so that drain plug (3) is directly at the

bottom.
2. Remove oil level plug (2) and oil filler plug (1), then
remove drain plugs (3) and (4), and drain the oil.
3. After draining the oil, tighten plugs (3) and (4).
4. Add engine oil to the specified level through the hole in oil
filler plug (1).
5. After adding oil, check that the oil is at the specified level,
refering to "CHECK OIL LEVEL IN FINAL DRIVE CASE,
ADD OIL (PAGE 4-49)".
CLEAN BREATHER
1. Remove mounting bolts (2) at the top of filter cover (1),
then open cover to outside using the hinge at the bottom
as the fulcrum.
4-63
3. Remove breather (4), wash with clean diesel fuel and

rinse the dirt out from the inside.
Power train case breather (1 place)
4. Tighten filter cover (1), then tighten bolt (2).
NOTICE
● When installing seal (3), always close filter cover (1)
first.
● If the filter cover is closed after installing the seal, the
seal will be damaged.
5. Install frame seal (3).
4-64
GREASE UNIVERSAL JOINT
WARNING
The undercover is heavy. Never try to open or close the cover when directly beneath it. When removing
bolts (2), carry out the work from the rear below the cover so that you can easily get out of the way.
1. Remove the undercover at the rear bottom of the chassis

as follows.
1) Remove 2 bolts (1) at the front of the machine.
2) Support the cover with your elbow while gradually

removing 2 bolts (2) at the rear of the machine.
3) Lower the cover gradually to open it.
2. Apply grease to the grease fittings (2 places) shown by

arrows.
4-65
REPLACE CORROSION RESISTOR CARTRIDGE

1. Screw in valve (1) at the top of the corrosion resistor.
2. Using a filter wrench, turn cartridge (2) to the left to

remove it.
3. Apply engine oil to the sealing surface of a new cartridge,

then install it to the filter holder.
4. When installing, screw in cartridge until seal comes in

contact with sealing surface, then tighten approx. 2/3
turn.
5. Open valve (1).

Use Komatsu genuine cartridge.
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER

Please contact your Komatsu distributor to have the tightening portions checked.
CHECK PLAY OF TURBOCHARGER ROTOR

Please contact your Komatsu distributor to have the rotor play checked.
CHECK FOR LOOSE ROPS MOUNT BOLTS

(If equipped)
Check for loose and damaged bolts.
If any loose bolt is found, tighten to a torque of 927 ± 103N•m (94.5 ± 10.5kgf•m, 684 ± 76lbft)
If any damaged bolt is found, replace the bolt with a genuine Komatsu bolt.
4-66

Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time.
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER

ELEMET AND CLEAN SUCTION STRAINER
WARNING
1. Lower the blade to the ground securely, stop the engine

and slowly turn the cap of oil filler (F) to release the inter-
nal pressure. Then, remove the cap.
2. Remove the cover from the bottom of the hydraulic tank.
3. Remove plug (1) at the bottom of the hydraulic tank,

loosen drain valve (2) and drain oil, then tighten the drain
valve (2).
After tightening, install plug (1).
When loosening drain valve (2), be careful not to get oil
on you.
4. To drain the oil in hydraulic oil filter case (7), release the
grommet under the fender and remove drain plug (3).
Be careful to avoid getting oil on yourself when remove
drain plug (3).
5. Remove mounting bolts (5) at the top of filter cover (4),

then open cover to outside using the hinge at the bottom
as the fulcrum.
4-67
7. Remove mounting bolts (8) of filter (7), then remove

cover (9).
8. Take out element (10).
9. Clean the inside of the case and the removed parts, then
install a new element.
Always use a genuine Komatsu element.
10. Install drain plug (3).
11. After installing, loosen air bleed plug (11), start the
engine, and when oil oozes out, tighten plug (11).
12. CLose filter cover (4), then tighten bolt (5).
NOTICE
● When installing seal (6), always close filter cover (4)
first.
● If the filter cover is closed after installing the seal, the
seal will be damaged.
13. Install frame seal (6).
14. Add the replacement amount of engine oil through oil

filler port (F).
15. After filling with oil, check that the oil is at the correct
level. For details, see "CHECK OIL LEVEL IN HYDRAU-
LIC TANK, ADD OIL (PAGE 4-50)".
4-68
REPLACE HYDRAULIC TANK BREATHER ELEMENT
WARNING
1. Remove the cap of oil filler (F) at the top of the hydraulic
tank.
2. Replace element (1) inside the cap.
4-69
CLEAN ENGINE BREATHER ELEMENT
WARNING
● The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
Wait for the temperature to go down before cleaning the engine breather.
● When using compressed air, there is a hazard that dirt may be blown up and cause serious injury.
Always use safety glasses, dust mask, or other protective equipment.
1. Wipe away dust around the breather.
2. Remove breather.
3. Wash the whole breather in diesel oil or flushing oil, then

blow it dry with compressed air.
4. Replace the breather O-ring with a new one, coat with

engine oil, and install.
CHANGE OIL IN DAMPER CASE
WARNING
● The oil is very hot just after the operation. Wait until
the oil temperature drops, then start the work.
● The undercover is heavy. Do not open or close it just

under it. When removing bolt (2), stand after the cover
so that you can escape at any moment.
● When removing drain plug (5) of the damper case,

take care not to get oil over yourself.
● Refill capacity: 1.7 liter (0.45 US gal)

machine body as follows.

machine body.
4-70
2. Remove oil level plug (3) and oil filler plug (4), then
remove drain plug 5 to drain the oil. After the all oil is
drained, tighten plug (5).
3. Add engine oil through the hole of oil filler plug (4) until
the oil level reaches the bottom edge of the hole of oil
level plug (3).
4. After refilling the oil, tighten plugs (3) and (4).
CLEAN, CHECK TURBOCHARGER

Contact your Komatsu distributor for cleaning or inspection.
CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.
CHECK ALTERNATOR, STARTING MOTOR

The brush may be worn or the bearing may have run out of grease, so contact your Komatsu distributor for inspec-
tion or repair.
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, please contact your Komatsu distributor.
4-71

Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be carried out at the same time.
CHECK WATER PUMP

Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any abnormality is
found, please contact your Komatsu distributor for repairs or replacement.
4-72
SPECIFICATIONS
51
5-1
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Straight tiltdozer with Cab + ROPS
Item Unit D85ESS-2A
Operating weight
kg (lb) 18,230 (40,197)
(without operator)
Name of engine — Komatsu 6D125E-2 diesel engine

Engine horsepower kW (HP)/rpm 149 (200)/1,950
A Overall length mm (ft in) 5,550 (18’3")
B Overall height mm (ft in) 3,160 (10’4")

C Overall width mm (ft in) 3,620 (11’11")
Travel speed Forward km/h (MPH) 3.9/6.8/10.6 (2.4/4.2/6.6)

(1st/2nd/3rd) Reverse km/h (MPH) 5.0/8.6/13.4 (3.1/5.3/8.3)
5-2
ATTACHMENTS, OPTIONS
61
WARNING
Please read and make sure that you understand the safety
volume before reading this section.
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 distribu-
tor first.
If you do not contact Komatsu, we cannot accept any responsibility for any accidents or failures.
WARNING
General precautions
● Attachments are strong tools. Handle them correctly to prevent serious injury.
● Read the operation manual for each attachment carefully, and do not use the machine before you
understand the operation method completely.
If you lose your operation manual, be sure to order another copy from the manufacturer or your
● Place your foot on a pedal only when necessary for prevention of serious injury caused by malfunc-
tion.
Precautions for removal and installation
When removing or installing an attachment, observe the following items and work safely.
● Install or remove an attachment on a level and hard place.
● When working by two persons or more in cooperation, decide signs and work according to them.
● When carrying a heavy part (25 kg (55 lb) or heavier), use a crane.
● When removing a heavy part, be sure to prepare a support for it in advance.

When removing it with a crane, take care of its center of gravity particularly.
● It is dangerous to work on a part lifted up with a crane. Be sure to place the part on a stand and check
safety.
● When leaving a attachment removed or installing it, place it in a stable position.
● Do not stand under a part lifted up with a crane.

Stay a place apart from the part where your are safe even if the part falls.
NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an unqualified per-
son.
For details of removal and installation operations, contact your Komatsu distributor.
6-2
ATTACHMENTS, OPTIONS SUSPENSION SEAT
SUSPENSION SEAT
(Deluxe seat)
ADJUSTMENT
WARNING
● Adjust the seat position at the beginning of each shift or when operators change.
● Adjust the seat so that the brake pedal can be depressed all the way 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 oper-
ate, then release the lever.
Fore-aft adjustment: 160 mm (6.3 in) (8 stages)
(B) Weight adjustment of seat
Turn knob (2) under the seat to match the weight adjustment
scale with your own weight.
The weight can be adjusted within a range of 50 to 120 kg (110
to 265 lb)
If you want to make the seat softer, turn the weight adjustment to a lower weight; if you want to make the seat
harder, adjust to a higher weight.When operating on uneven surfaces, adjust the seat to a harder setting.
(C) Adjuster reclining angle
NOTICE
When reclining the seat back to the rear, check the space behind, and adjust to a suitable position.
Pull lever (3), set the seatback to a position where it is easy to operate, then release the lever.
(D) Height adjustment of seat
● Turn lever (4) to adjust the height of the seat.

● If the lever is turned clockwise, the seat is heightened. If the former is turn counterclockwise, the latter is low-
ered. If you apply your weight to the seat, the lever becomes heavy. Accordingly, do not apply your weight.
After adjusting the height, release the lever to lock the seat.
(Height adjustment distance: Stepless, 50 mm (2.0 in))
(E) Adjusting direction of seat
Pull up lever (6) to unlock the seat, and the seat can be turned by hand to the position of 15° on the right. After
changing the direction of the seat, return the lever securely to lock the seat.
● Angling the seat to the right makes it easier to carry out ripper operations or scraper towing operations or oper-
ations facing the rear.
6-3
HEADREST ATTACHMENTS, OPTIONS
HEADREST
Removal of headrest
Pull up the headrest.
REMARK
The headrest cannot be fixed to halfway.
6-4
ATTACHMENTS, OPTIONS HANDLING ACCUMULATOR
HANDLING ACCUMULATOR
WARNING
On machines equipped with an accumulator, for a short time after the engine is stopped, if the blade con-
trol lever is moved to the LOWER position, the work equipment will move down under its own weight.
After stopping the engine, always place the work equipment lever in the LOCK position.
The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is handled in
the wrong way. Always observe the following precautions.
● Never make any hole in the accumulator or expose it to flame or fire.
● Do not weld any boss to the accumulator.
● When disposing the accumulator, it is necessary to release the gas from the accumulator, so please
contact your Komatsu distributor.
The accumulator is a device to store the pressure in the control

circuit, and when it is installed, the control circuit can be oper-
ated for a short time even after the engine is stopped.
Therefore, if the control lever is moved in the direction to lower

the work equipment, it is possible for the work equipment to
move under its own weight.
The accumulator is installed to the position shown in the dia-

gram on the right.
6-5
HANDLING ACCUMULATOR ATTACHMENTS, OPTIONS
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON

MACHINE EQUIPPED WITH ACCUMULATOR
WARNING
The hydraulic system is always under internal pressure, so release the pressure inside the circuit before
checking or replacing the piping and hoses. There is danger that high- pressure oil may spurt out and
cause serious personal injury.
● When removing the oil filler cap, oil may spurt out, so remove the cap slowly to release the internal
pressure, then remove the cap carefully.
● The pressure cannot be released completely, so when removing the work equipment circuit, loosen
the screws slowly, and do not stand in the direction where the oil spurts out.
1. Stop the machine on firm level ground.
2. Lower the blade completely to the ground, then stop the

engine.
3. Operate the blade control lever fully in each direction

within 15 seconds after the engine stops to release the
internal pressure.
4. Loosen oil filler cap (F) at the top of the hydraulic tank to
release the internal pressure.
6-6
ATTACHMENTS, OPTIONS EQUIPPING THE FIRE EXTINGUISHER AND THE FIRST-AID KIT
EQUIPPING THE FIRE EXTINGUISHER AND THE

FIRST-AID KIT
Equipping the fire extinguisher and the first-aid kit at the illustrated position needs brackets (if equipped). The fire
extinguisher and the first-aid kit can be installed to the positions shown in the following illustration.
(1)First-aid kit
(2)Fire extinguisher
For brackets, please contact your Komatsu distributor.
6-7
HANDLING TOWING WINCH ATTACHMENTS, OPTIONS
HANDLING TOWING WINCH
EXPLANATION OF CONTROLS
Winch lever
● Inching operation
(A) HOLD
(B) INCHING
(C) FLOAT
● Clutch operation
(1) NORMAL ROTATION
(2) REVERSE ROTATION
(3) SLOW REVERSE ROTATION
(N) Neutral
Winch lock knob

This locks the winch lever at the neutral position.
6-8
ATTACHMENTS, OPTIONS HANDLING TOWING WINCH
OPERATION

● When carrying out winch operations, always stop the
machine, except when the brake is released.
● When moving the machine, place the winch lever at the
neutral position, and always set winch lock knob (1) to the
LOCK position.
● Inching operations cause damage to the disk, so avoid
continuing inching operations for long periods.
TOWING WINCH OPERATIONS

1. When using the towing winch, use the overwinding
method - that is, wind the wire rope in and out from the
top of the drum.
2. After starting the engine, set the winch lock knob to the
FREE position.
3. Operate as follows.
Normal direction of rotation
Pull the winch lever to position (1).
The drum will rotate in the normal direction and the wire
rope will wind in.
Reverse rotation
Push the winch lever to position (2).
The drum will rotate in the reverse direction and the wire
rope will wind in.
Slow reverse rotation
Place the winch lever at position (3).
The drum will rotate slowly in the reverse direction and
the wire rope will wind in.
● The inching operation is used with the brake released to carry out fine control of the load held on the
rope.
When winding the rope in or out, the inching operation is unnecessary.
● When the lever is released, it will return to the neutral or HOLD position, but with the inching operation, if
it is pushed in fully, the notch will catch and it will be held in position with the brake still released. This is
dangerous, so never push it in fully. Pull the lever by hand to return it.
● The winding-in speed of the rope is determined by the engine speed, but the speed in reverse rotation is
faster than the normal rotation, so adjust with the speed control.
6-9
CLUTCH
The clutch is normally kept disengaged by a spring, but when the clutch is operated, the clutch is engaged by
hydraulic force, and the drum rotates to wind the rope in or out.
The clutch is adjusted before it is shipped from the factory, so if there are any problems with the clutch, please con-
tact your Komatsu distributor for inspection or repair.
BRAKE
The brake is normally kept engaged by a spring, but for inching operations or when operating in the normal or
reverse directions, the hydraulic piston of the brake is actuated to release the brake.
Carry out this operation only when winding out under no load.
When the winch lever is at the neutral position, if the rope on the drum is wound out, it means that the brake is not
having effect, so please contact your Komatsu distributor for inspection or repair.
WIRE ROPE HANDLING

Because the wire rope is repeatedly tightening and loosening it damages quickly, so it should be checked for dam-
age after operations, and changed in the following conditions:
● When rope diameter is worn more than 7%.
● When the rope has developed a kink from twisting.
● When it is badly out of shape or rusted.
When replacing the wire rope, use a normal Z-lay seal type 19 wire, 6 strand lay 7 x 7 + 6 x S (19) core 1, W,
R, C.
ADJUSTING SPEED OF ROTATION FOR SLOW REVERSE ROTATION

Adjust as follows:
Watch the rotation of the drum and adjust adjustment plate (1).
When it reaches a suitable speed, tighten bolt (2) to hold plate
(1) in position.
6-10
ATTACHMENTS, OPTIONS HANDLING TOWING WINCH
MAINTENANCE
The occurrence of failures and the life of the machine are influenced directly by whether adding oil or grease or
other maintenance is carried out properly, so determine the day for carrying out periodic maintenance.

CHECK BOLTS AND NUTS FOR LOOSENING OR MISSING
CHECK WIRE ROPE FOR WEAR OR DAMAGE
INITIAL 250 HOURS SERVICE

CHANGE OIL IN WINCH CASE, CLEAN STRAINER
1. Remove drain plug (P) to drain the oil, then tighten plug (P).
2. Remove a strainer cover (H). Remove a strainer (J) and a

case (K), then clean up them. After that install them in
order.
NOTICE
Clean up a strainer (J) by flushing oil and after that remove
dust, dirt etc. completely with air-blow.
3. Add the specified amount of engine oil through oil filter (F).
Above 0ºC: Use engine oil CLASS-CD SAE30W.
Below 10ºC: Use engine oil CLASS-CD SAE10W.
Oil capacity: 76 ¬ (20.0 US gal)
4. After changing the oil, check oil level through plug (G).
REMARK
When draining or refilling oil, park the machine horizontally.

CHANGE OIL IN WINCH CASE, CLEAN STRAINER
1. Remove drain plug (P) to drain the oil, then tighten plug (P).
2. Remove a strainer cover (H). Remove a strainer (J) and a

case (K), then clean up them. After that install them in
order.
NOTICE
Clean up a strainer (J) by flushing oil and after that remove
dust, dirt etc. completely with air-blow.
3. Add the specified amount of engine oil through the oil

filler (F).
Above 0ºC: Use engine oil CLASS-CD SAE30W.
Below 10ºC: Use engine oil CLASS-CD SAE10W.
Oil capacity: 76 ¬ (20.0 US gal)
4. After changing the oil, check oil level through plug (G).
REMARK
When draining or refilling oil, park the machine horizontally.
6-11
SPECIFICATIONS
● Weight of winch proper (control + U/J 40 kg)
1290 kg (2844 lb)
(dry weight)
● Tractive force of cable
Bare drum 31400 kg (69237 lb)

Full drum 18200 kg (40131 lb)
● Cable winding speed
Normal direction Bare drum 28 m (91.8 ft)/min

Full drum 48 m (157.4 ft)/min
Reverse direction Bare drum 63 m (206.6 ft)/min
Full drum 110 m (360.8 ft)/min
● Dimensions of cable (diameter x length) 26 mm (1 in) x 65 m (213.2 ft)
6-12
INDEX
INDEX
7
A CHANGE OIL IN POWER TRAIN CASE, CLEAN

ACTION IF FIRE OCCURS ................................. 2-13 STRAINERS (POWER TRAIN STRAINER,
ADDITIONAL WORK LAMP SWITCH ................ 3-15 SCAVENGING PUMP STRAINER) ............... 4-60
ADJUST AMOUNT OF TILT POWER TILT ........ 3-98 CHARGE LAMP ........................................... 3-8, 3-11
ADJUST ANGLE OF BLADE EDGE ................... 3-94 CHASSIS .......................................................... 3-128
ADJUST IDLER CLEARANCE ............................ 4-37 CHECK AFTER FINISHING WORK ................. 3-103
ADJUSTING BRACE OF ANGLE BLADE .......... 3-96 CHECK AFTER INSPECTION AND
ADJUSTING SHIMS IN ASSEMBLING MAINTENANCE WORKS ................................. 4-4
WORK EQUIPMENT ...................................... 3-95 CHECK AFTER STOPPING ENGINE ................ 3-78
ADJUSTING SHIMS, ADJUSTING TENSION AT CHECK ALL TIGHTENING PARTS OF
WORK EQUIPMENT LINKS ........................... 4-38 TURBOCHARGER ......................................... 4-66
ADJUSTING TENSION OF CENTER BRACE .... 3-95 CHECK ALTERNATOR, STARTING MOTOR ... 4-71
ADJUSTING TILT FOR USING BLADE IN CHECK AND TIGHTEN TRACK SHOE
ANGLED POSTURE .................................... 3-101 BOLTS ........................................................... 4-27
ADJUSTMENT .................................................... 3-61 CHECK BEFORE STARTING ................... 3-50, 4-45
ADJUSTING POSTURE OF CHECK BEFORE STARTING ENGINE,
WORK EQUIPMENT ...................................... 3-94 ADJUST ......................................................... 3-48
AFTER COLD WEATHER ................................ 3-119 CHECK BRAKE PERFORMANCE ..................... 4-55
AFTER COMPLETION OF WORK ................... 3-119 CHECK DOOR LATCH ....................................... 4-33
AFTER RUNNING OUT OF FUEL .................... 3-121 CHECK DOOR LOCK STRIKER ........................ 4-32
AFTER STORAGE ............................................ 3-120 CHECK ELECTRICAL INTAKE AIR HEATER ... 4-28
AIR CONDITIONER ............................................ 3-39 CHECK ENGINE VALVE CLEARANCE,
ALWAYS APPLY LOCK WHEN LEAVING ADJUST ......................................................... 4-71
OPERATOR'S SEAT ........................................ 2-9 CHECK FAN BELT TENSION, ADJUST ............ 4-52
ALWAYS USE CLEAN WASHER FLUID............... 4-2 CHECK FOR LOOSE ROPS MOUNT BOLTS ... 4-66
APPOINT LEADER WHEN WORKING WITH CHECK IDLER OIL LEVEL, ADD OIL ................ 4-36
OTHERS ......................................................... 2-27 CHECK LEVEL OF BATTERY ELECTROLYTE 4-51
ASHTRAY ........................................................... 3-30 CHECK OIL LEVEL IN DAMPER CASE,
ATTACHMENTS ................................................. 2-30 ADD AND CHANGE OIL ................................ 4-62
AVOID MIXING OILS ............................................. 4-3 CHECK OIL LEVEL IN FINAL DRIVE CASE,
ADD OIL ......................................................... 4-49
CHECK OIL LEVEL IN HYDRAULIC TANK,
B ADD OIL ......................................................... 4-50
BATTERY .................................................2-24, 3-118 CHECK PLAY OF TURBOCHARGER ROTOR .. 4-66
BATTERY HAZARD PREVENTION ................... 2-24 CHECK SERVICE METER ................................... 4-2
BE CAREFUL ABOUT ASBESTOS DUST ......... 2-16 CHECK TRACK TENSION ................................. 4-26
BEFORE STORAGE ......................................... 3-120 CHECK VIBRATION DAMPER .......................... 4-71
BLADE CONTROL LEVER ................................. 3-22 CHECK WATER PUMP ...................................... 4-72
BRAKE LOCK LEVER ........................................ 3-19 CHECK WINDOW WASHER FLUID LEVEL,
BRAKE PEDAL ................................................... 3-21 ADD FLUID .................................................... 4-34
BREAKING IN THE NEW MACHINE .................. 3-73 CHECK, ADJUST AIR CONDITIONER .............. 4-31
CHECK, CLEAN AND REPLACE
AIR CLEANER ELEMENT ............................. 4-19
C CHECK, CLEAN FUEL STRAINER .................... 4-53
CAP, COVER WITH LOCK ................................. 3-28 CHECKING FOREIGN MATERIALS
CAR STEREO ..................................................... 3-31 DRAINED OIL ................................................... 4-2
CARRYING OUT KOWA CHECKING SIGNALMAN'S SIGNALS AND
(Komatsu Oil Wear Analysis) ............................ 4-7 SIGNS ............................................................ 2-16
CHANGE OIL IN DAMPER CASE ...................... 4-70 CHECKS AFTER OPERATION .......................... 2-19
CHANGE OIL IN ENGINE OIL PAN, REPLACE CHECKS BEFORE STARTING ENGINE ........... 2-17
ENGINE OIL FILTER CARTRIDGE ............... 4-59 CIGARETTE LIGHTER ....................................... 3-16
CHANGE OIL IN FINAL DRIVE CASE ............... 4-63 CLEAN AIR CONDITIONER AIR FILTER
CHANGE OIL IN HYDRAULIC TANK, REPLACE (FRESH/RECIRC FILTER) ............................ 4-56
HYDRAULIC OIL FILTER ELEMET AND CLEAN CLEAN BREATHER ........................................... 4-63
SUCTION STRAINER .................................... 4-67 CLEAN ENGINE BREATHER ELEMENT .......... 4-70
7-1
INDEX
CLEAN INSIDE OF COOLING SYSTEM ............4-23 EXPLANATION OF PARTS .......................3-39, 3-45

CLEAN INSIDE OF TRUNNION COVER .........4-44-1
CLEAN OIL AND GREASE....................................4-2
F
CLEAN, CHECK RADIATOR FINS .....................4-30
FELLING TREES, REMOVING STUMPS .......... 3-93
CLEAN, CHECK TURBOCHARGER ..................4-71
FILTERS ............................................................... 4-8
CLOTHING AND PERSONAL
FIRE EXTINGUISHER AND FIRST AID KIT ........ 2-8
PROTECTIVE ITEMS .......................................2-8
FIRE PREVENTION ........................................... 2-12
COLD WEATHER OPERATION .......................3-117
FOREWORD ........................................................ 1-2
COMPRESSED AIR ............................................2-33
FRONT/REAR, LEFT/RIGHT DIRECTIONS
CONTROL LEVERS AND PEDALS ....................3-18
OF MACHINE ................................................... 1-5
COOLANT .........................................................3-117
FUEL ..................................................................... 4-6
COOLANT AND WATER FOR DILUTION ............4-6
FUEL AND LUBRACANTS ............................... 3-117
COOLING OPERATION .....................................3-41
FUEL AND LUBRICANTS TO
CREANING AIR FILTER ............................3-44, 3-47
MATCH THE AMBIENT TEMPERATURE ....... 4-4
CRUSHING OR CUTTING PREVENTION .........2-11
FUEL CONTROL LEVER ................................... 3-19
CUTTING INTO HARD OR FROZEN
FUEL GAUGE ....................................................... 3-7
GROUND OR DITCHING ...............................3-93
FUEL STRAINER .................................................. 4-2
FUSE .................................................................. 3-24
D FUSE CAPACITY AND CIRCUIT NAME ............ 3-24
DECELERATION PEDAL ...................................3-21
DEFINED LIFE PARTS .............................4-15,4-16
G
DO NOT DISASSEMBLE RECOIL SPRING .......2-31
GAUGE PANEL .................................................. 3-10
DO NOT DROP THINGS INSIDE MACHINE.........4-3
GENERAL PRECAUTIONS ........................... 2-8, 6-2
DO NOT GO CLOSE TO HIGH-VOLTAGE
GENERAL VIEW .................................................. 3-2
CABLES .........................................................2-15
GENERAL VIEW OF CONTROLS AND
DOOR-OPEN LOCK ...........................................3-27
GAUGES .......................................................... 3-3
DOZING ..............................................................3-92
GENERAL VIEW OF MACHINE ........................... 3-2
DRAIN WATER, SEDIMENT FROM
GLOW SIGNAL ................................................... 3-11
FUEL FILTER .................................................4-52
GLOW SIGNAL LAMP .......................................... 3-8
DRAIN WATER, SEDIMENT FROM
GLOW SWITCH .................................................. 3-13
FUEL TANK ....................................................4-46
GREASE ............................................................... 4-6
DURING STORAGE .........................................3-120
GREASE DOOR HINGE ..................................... 4-32
DUSTY WORKSITES ............................................4-3
GREASE EQUALIZER BAR CENTER PIN ........ 4-48
GREASE EQUALIZER BAR SIDE PIN ............... 4-48
E GREASE PUMP HOLDER ................................. 3-30
ELECTRIC POWER TAKE-OUT ADAPTER .......3-26 GREASE UNIVERSAL JOINT ............................ 4-65
ELECTRICAL SYSTEM ....................................3-126 GUIDE TO MAINTENANCE ................................. 4-2
EMERGENCY EXIT FROM OPERATOR’S
CAB ................................................................2-16
H
ENGINE ............................................................3-130
HANDLING ACCUMULATOR .............................. 6-5
ENGINE HYDRAULIC OIL TEMPERATURE
HANDLING HIGH-PRESSURE HOSES ............. 2-32
CAUTION LAMP .............................................3-11
HANDLING OIL, FUEL, COOLANT, AND
ENGINE OIL PRESSURE CAUTION LAMP .........3-8
PERFORMING OIL CLINIC ............................. 4-5
ENGINE SERIAL NO. PLATE AND POSITION ....1-6
HANDRAILS AND STEPS .................................. 2-10
ENGINE WATER TEMPEARTURE GAUGE ........3-7
HEAD LAMP SWITCH ........................................ 3-14
ENGINE WATER TEMPERATURE
HEADREST .......................................................... 6-4
CAUTION LAMP ...............................................3-7
HEATER ............................................................. 3-45
ENGINE WATER TEMPERATURE GAUGE ......3-10
HEATING OPERATION ...................................... 3-42
ENSURE GOOD VISIBILITY ..............................2-15
HORN SWITCH .................................................. 3-14
EQUIPPING THE FIRE EXTINGUISHER AND
HOT AND COOL BOX ........................................ 3-29
THE FIRST-AID KIT .........................................6-7
HYDRAULIC SYSTEM - AIR BLEEDING ............. 4-4
EVERY 50 HOURS SERVICE ............................4-46
EVERY 250 HOURS SERVICE ..........................4-47
EVERY 500 HOURS SERVICE ..........................4-57 I
EVERY 1000 HOURS SERVICE ........................4-60 IF ABNORMALITIES ARE FOUND ...................... 2-8
EVERY 2000 HOURS SERVICE ........................4-67 IF BATTERY IS DISCHARGED ........................ 3-122
EVERY 4000 HOURS SERVICE ........................4-72 INSIDE OPERATOR'S COMPARTMENT ............ 2-9
EXPLANATION OF COMPONENTS ...........3-6, 3-31 INSPECTION AND ADJUSTMENT .................. 3-106
7-2
INDEX
INSPECTION AND REPAIR ............................. 3-107 NORMAL TURNING ........................................... 3-86

INSPECTION DURING OFF-SEASON .............. 3-43
INTRODUCTION ................................................... 1-5
IT IS PROHIBITED TO KEEP THE DOOR OPEN O
DURING OPERATIONS ................................. 3-90 OIL ........................................................................ 4-5
IT IS PROHIBITED TO MODIFY OPERATE CAREFULLY ON SNOW .................. 2-21
THE CAB GLASS IN ANY WAY OPERATION .............................................. 2-19, 3-48
THAT OBSTRUCT THE VIEW ....................... 3-91 OPERATION AND CHECK BEFORE
STARTING ENGINE ...................................... 3-64
OPERATION MANUAL STORAGE .................... 3-29
K OPERATION METHOD .................................... 3-105
KEEP MACHINE CLEAN ...................................... 2-9 OPERATIONS AND CHECKS AFTER
KEEP WORK PLACE CLEAN AND TIDY ........... 2-27 STARTING ENGINE ...................................... 3-73
KOMATSU GENUINE OILS................................... 4-2 OTHER TROUBLE ........................................... 3-126
KOMATSU GENUINE REPLACEMENTPARTS .... 4-2 OUTLINE OF SERVICE ....................................... 4-5
L
P
LAMP .................................................................. 3-17
PARKING MACHINE ............................... 2-22, 3-102
LIFTING MACHINE ........................................... 3-115
PERMISSIBLE WATER DEPTH ......................... 3-90
LOADING .......................................................... 3-111
POSITION OF SERVICE METER ........................ 1-7
LOADING AND UNLOADING ............................. 2-23
POSITIONS OF SAFETY PICTOGRAMS ............ 2-4
LOADING, UNLOADING WORK ...................... 3-111
PRECAUTION WHEN USING ............................ 3-38
LOCKING .......................................................... 3-104
PRECAUTION WHEN USING
LONG-TERM STORAGE .................................. 3-120
AIR CONDITIONER ....................................... 3-43
LOOKING THE INSPECTION COVERS ............... 4-4
PRECAUTION WITH HIGH-PRESSURE OIL .... 2-32
LUBRICATING .................................................... 4-47
PRECAUTIONS FOR ATTACHMENTS ............. 2-14
PRECAUTIONS FOR BLIND SPOTS
M CAUSED BY CAB STAY ................................ 3-91
MACHINE OPERATION ..................................... 3-79 PRECAUTIONS FOR CHARGING BATTERY .. 3-123
MACHINE SERIAL NO. PLATE AND PRECAUTIONS FOR LOW TEMPERATURE... 3-117
POSITION ......................................................... 1-6 PRECAUTIONS FOR MAINTENENCE .............. 2-27
MAINTENANCE FOR AIR CONDITIONER ........ 2-33 PRECAUTIONS FOR MOVING MACHINE
MAINTENANCE SCHEDURE CHART ............... 4-17 FORWARD OR IN REVERSE ....................... 2-19
METHOD OF ANGLING BLADE ....................... 3-100 PRECAUTIONS FOR OPENING AND CLOSING
METHOD OF OPENING AND ENGINE SIDE COVER .................................... 4-3
CLOSING CAP WITH LOCK .......................... 3-28 PRECAUTIONS FOR OPERATION .......... 2-17, 3-90
METHOD OF OPENING AND PRECAUTIONS FOR WORK UNDER MACHINE
CLOSING COVER WITH LOCK ..................... 3-29 AND WORK EQUIPMENT ............................. 2-30
METHOD OF OPERATION ................................ 3-46 PRECAUTIONS IN COLD AREAS ..................... 2-18
METHOD OF RELEASING PRESSURE IN PRECAUTIONS ON SLOPES ............................ 3-90
OPERATING CIRCUIT ON MACHINE PRECAUTIONS RELATED TO SAFETY ............. 6-2
EQUIPPED WITH ACCUMULATOR ................ 6-6 PRECAUTIONS WHEN INSTALLING
METHOD OF USING HYDRAULIC HOSES ....................................... 4-4
AUTOMATIC AIR BLEED MECHANISM ........ 4-58 PRECAUTIONS WHEN REMOVING
METOD OF OPERATION ................................... 3-36 WORK EQUIPMENT .................................... 3-109
MONITOR CAUTION CANCAL SWITCH ............. 3-9 PRECAUTIONS WHEN STARTING ................... 2-18
MONITOR CAUTION LAMP ................................. 3-9 PRECAUTIONS WHEN TRAVELING ................ 2-20
MONITOR PANEL ................................................ 3-6 PRECAUTIONS WHEN TRAVELING
MOUNTING AND DISMOUNTING ..................... 2-11 UP OR DOWN HILLS .................................... 3-90
MOVING MACHINE OFF .................................... 3-79 PRECAUTIONS WHEN USING HAMMER ........ 2-30
PRECAUTIONS WHEN USING HIGH-PRESSURE
GREASE TO ADJUST TRACK TENSION ...... 2-31
N PRECAUTIONS WHEN USING ROPS .............. 2-13
NECESSARY INFORMATION .............................. 1-6 PREVENTION METHOD OF
NO PEOPLE ON ATTACHMENTS ..................... 2-11 ENTRY OF DUST .......................................... 3-43
NO UNAUTHORIZED PERSONNEL PREVENTION OF BURNS ................................. 2-12
INTO AREA .................................................... 2-29 PROCEDURE FOR BLEEDING AIR OF
NOISE ................................................................. 2-30 HYDRAULIC SYSTEM ................................... 4-37
NORMAL STARTING .......................................... 3-66 PROCEDURE FOR REPLACING RECEIVER ... 3-44
7-3
INDEX
PROPER TOOLS ................................................2-29 STOP ENGINE BEFORE CARRYING OUT

PROSEDURE FOR LIFTING OPERATIONS ...3-115 INSPECTION AND MAINTENANCE ............. 2-28
STOPPING ENGINE .......................................... 3-76
STOPPING MACHINE ........................................ 3-81
R STORING OIL AND FUEL .................................... 4-8
REAR LAMP SWITCH ........................................3-14 SUSPENSION SEAT ............................................ 6-3
RECOMMENDED BRANDS, RECOMMENDED SWITCHES ......................................................... 3-12
QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL ..............................4-13
RECOMMENDED FUEL, COOLANT, AND T
LUBRICANT ...................................................4-11 TABLE OF ENTER SERIAL NO. AND
RELATING TO ELECTRIC SYSTEM ....................4-9 DISTRIBUTOR ................................................. 1-7
REMOVE AND INSTALL BATTERY .................3-123 TIPS FOR LONGER UNDERCARRIAGE
REMOVING BATTERY TERMINAL ....................2-31 LIFE .............................................................. 3-105
REMOVING CAB ..............................................3-109 TOOL BOX ......................................................... 3-30
REPAIR WELDING .............................................2-31 TORQUE LIST .................................................... 4-14
REPLACE CORROSION RESISTOR TOWING ............................................................. 2-26
CARTRIDGE ..................................................4-66 TOWING THE MACHINE ................................. 3-121
REPLACE DOOR DAMPER ...............................4-32 TRANSMISSION OIL TEMPERATURE
REPLACE FUEL FILTER CARTRIDGE ..............4-57 CAUTION LAMP .............................................. 3-8
REPLACE HYDRAULIC TANK BREATHER TRANSMISSION OIL TEMPERATURE
ELEMENT .......................................................4-69 GAUGE ................................................... 3-7, 3-11
REPLACE POWER TRAIN OIL FILTER TRANSPORTATION ................................ 2-23, 3-109
ELEMENT .......................................................4-53 TRANSPORTATION MEANS ........................... 3-109
REPLACE WIPER BLADE ..................................4-35 TRAVELING ON SLOPES .................................. 2-21
REVERSE AND REPLACE THE END BITS AND TROUBLESHOOTING ...................................... 3-121
CUTTING EDGES ..........................................4-29 TURNING WHILE DESCENDING A SLOPE ...... 3-88
ROOM LAMP SWITCH .......................................3-16 TWO WORKERS FOR MAINTENANCE
WHEN ENGINE IS RUNNING ....................... 2-29
S
SAFETY ................................................................2-2 U
SAFETY AT WORKSITE ....................................2-14 UNAUTHORIZED MODIFICATION .................... 2-14
SAFETY CRITICAL PARTS ................................4-16 UNLOADING .................................................... 3-114
SAFETY FEATURES ............................................2-9 USE OF FUEL, COOLANT AND
SAFETY INFORMATION ......................................1-3 LUBRICANTS ACCORDING TO
SAFETY LABELS ...........................................2-4, 2-5 AMBIENT TEMPERATURE ........................... 4-12
SAFETY RULES ...................................................2-8 USING BRAKES ................................................. 2-21
SASH GLASS INTERMEDIATE LOCK ...............3-27
SECURING MACHINE ......................................3-112
SERVICE METER ........................................3-6, 3-10 V
SERVICE PROCEDURE ....................................4-19 VENTILATION FOR ENCLOSED AREAS .......... 2-16
SHIFTING BETWEEN FORWARD AND
REVERSE ......................................................3-84
SHIFTING GAER ................................................3-83 W
SHIPPING ...........................................................2-23 WALK-AROUND CHECK ................................... 3-48
SMOOTHING ......................................................3-92 WARMING UP OPERATIONS ........................... 3-73
SPECIFICATIONS ................................................5-2 WARNING TAG .................................................. 2-27
SPEED RANGE DISPLAY LAMP .......................3-17 WASTE MATERIAL ............................................ 2-32
STANDARD TIGHTENING TORQUES FOR WEAR PARTS .................................................... 4-10
BOLTS AND NUTS ........................................4-14 WEAR PARTS LIST ........................................... 4-10
STARTING ENGINE ..................................2-17, 3-66 WELDING INSTRUCTIONS .................................. 4-2
STARTING ENGINE WITH WHEN REQUIRED ............................................. 4-19
BOOSTER CABLE .......................................3-124 WHEN TOWING ................................................. 2-26
STARTING IN COLD WEATHER ..............3-67, 3-75 WINDOW WASHER LIQUID .............................. 2-13
STARTING SWITCH ...........................................3-13 WIPER SWITCH ................................................. 3-15
STARTING WITH BOOSTER CABLE ................2-25 WORK EQUIPMENT LOCK LEVER ................... 3-18
STEERING MACHINE ........................................3-86 WORK POSSIBLE USING BULLDOZER ........... 3-92
STEERING, DIRECTIONAL AND WORKING ON LOOSE GROUND ..................... 2-15
GEAR SHIFT LEVER .....................................3-20
7-4
MEMO
7-5
D85ESS-2A BULLDOZER
Form No. PEN01634-03
©2022
All Rights Reserved
Printed in Japan 08-2022
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PEN01634-03

BULLDOZER D85ESS -2A

Storage location for the Operation and Maintenance Manual:

Machine equipped with cab

Inside of right and left doors

Machine without cab

Back pocket of operator's seat

Example of safety message using signal word

Other signal words

This gives information that is useful to know.

Example of safety label using words

Safety labels using pictogram

● Cutting into hard or frozen ground or ditching.

● Felling trees, removing stumps

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE

MACHINE SERIAL NO. PLATE AND POSITION

ENGINE SERIAL NO. PLATE AND POSITION

POSITION OF SERVICE METER

Gauge panel specification

TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.

Engine serial No.

SAFETY INFORMATION...................................................................................................................................... 1-3

NECESSARY INFORMATION ............................................................................................................................. 1-6

SAFETY LABELS................................................................................................................................................. 2-4

GENERAL PRECAUTIONS ................................................................................................................................. 2-8

PRECAUTIONS FOR OPERATION ................................................................................................................... 2-17

PRECAUTIONS FOR MAINTENENCE .............................................................................................................. 2-27

EXPLANATION OF COMPONENTS.................................................................................................................... 3-6

CONTROL LEVERS AND PEDALS ......................................................................................................... 3-18

COLD WEATHER OPERATION ...................................................................................................................... 3-117

LONG-TERM STORAGE.................................................................................................................................. 3-120

OUTLINE OF SERVICE........................................................................................................................................ 4-5

WEAR PARTS .................................................................................................................................................... 4-10

RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................................................................................. 4-11

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-14

DEFINED LIFE PARTS ........................................................................................................................................ 4-15

MAINTENANCE SCHEDURE CHART ............................................................................................................... 4-17

SERVICE PROCEDURE .................................................................................................................................... 4-19

SUSPENSION SEAT ............................................................................................................................................ 6-3

HEADREST .......................................................................................................................................................... 6-4

HANDLING ACCUMULATOR.............................................................................................................................. 6-5

HANDLING TOWING WINCH .............................................................................................................................. 6-8

INDEX ................................................................................................................................................................... 7-1

GENERAL PRECAUTIONS .................................................................................................................................. 2-8

PRECAUTIONS FOR OPERATION ................................................................................................................... 2-17

PRECAUTIONS FOR MAINTENENCE .............................................................................................................. 2-27

POSITIONS OF SAFETY PICTOGRAMS

Safety label is attached on the back side of the

(11) Caution for blast site (09845-00480)

IF ABNORMALITIES ARE FOUND

CLOTHING AND PERSONAL PROTECTIVE ITEMS

● Always wear a hard hat and safety shoes. If the nature of

FIRE EXTINGUISHER AND FIRST AID KIT

● Be sure that fire extinguishers have been provided and

● Carry out periodic inspection and maintenance to ensure

KEEP MACHINE CLEAN

● If inspection and maintenance is carried out when the

INSIDE OPERATOR'S COMPARTMENT