Page 2 This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
Page 3 1. FOREWORD...
Page 4 1. FOREWORD...
Page 5: Safety Information
Safety precautions are described in SAFETY from page 1-1. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.
Page 6: Intended Use
If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user.
Page 7 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.1 MACHINE SERIAL NO. PLATE POSITION Under the front of the console box on the right side of the operator’s seat. 4.2 ENGINE SERIAL NO. PLATE POSITION On the upper left side of the engine cylinder block, when seen from the fan.
Page 8: Table Of Contents
5. CONTENTS 1. Foreword ............................0- 1 2. Safety information ..........................0- 4 3. Introduction ............................0- 5 4. Location of plates, table to enter serial No. and distributor ............0- 6 SAFETY 6. General precautions .......................... 1- 2 7. Precautions during operation ......................1- 8 Before starting engine ......................
Page 9 5. CONTENTS 12. Operation ............................2-32 12.1 Check before starting engine ....................2-32 12.2 Starting engine ........................2-48 12.3 Operations and checks after starting engine ............... 2-52 12.4 Moving machine ........................2-54 12.5 Shifting gear ..........................2-56 12.6 Shifting between forward and reverse ................. 2-57 12.7 Steering machine ........................
Page 10 5. CONTENTS 19. Wear parts list ........................... 3- 9 20. Use of fuel, coolant and lubricants according to ambient temperature ........3-11 21. Standard tightening torques for bolts and nuts ................3-13 21.1 Introduction of necessary tools ..................... 3-13 21.2 Torque list ..........................
Page 11: Safety
SAFETY ¤ WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equip- ment and attachments.
Page 12: General Precautions
‡ Check that all protective equipment functions properly before using. UNAUTHORIZED MODIFICATION Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification.
Page 13: Mounting And Dismounting
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 6. GENERAL PRECAUTIONS ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT ‡ When standing up from the operator’s seat, always place the safety lock levers securely in the LOCK position.
Page 14 ¤ WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly flammable and can be hazardous. Always observe the following: ‡...
Page 15 ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be hazardous to your health if it is inhaled. Komatsu does not use asbestos in its products, but if you handle materials containing asbestos fibers, follow the guidelines given below: ‡ Never use compressed air for cleaning.
Page 16 ‡ When installing and using an optional attachment, read the instruction manual for the attachment and the information related to attachments in this manual. ‡ Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.
Page 17 ‡ When carrying out disassembly or maintenance of the accumulator, or when disposing of the accumulator, it is necessary to release the gas from the accumulator. A special air bleed valve is necessary for this operation, so please contact your Komatsu distributor. Gas in accumulator © See “11.14 HANDLING ACCUMULATOR”.
Page 18: Precautions During Operation
7. PRECAUTIONS DURING ¤ WARNING: For reasons of safety, always OPERATION follow these safety precautions. 7.1 BEFORE STARTING ENGINE SAFETY AT WORKSITE ‡ Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. ‡ Check the terrain and condition of the ground at the worksite, and determine the best and safest method of operation.
Page 19 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PRECAUTIONS FOR SLIDING GLASS INTERMEDIATE LOCK The sliding glass intermediate lock is to prevent rattling of the glass. Even when the lock is used, the glass may move because of the shock when starting or stopping suddenly.
Page 20: After Starting Engine
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. 7.2 AFTER STARTING ENGINE CHECKS AFTER STARTING ENGINE Failure to carry out the checks properly after starting the engine will lead to delays in discovery of abnormalities, and this may lead to serious injury or damage to the machine.
Page 21 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PRECAUTIONS WHEN TRAVELING ‡ Never turn the key in the starting switch to the OFF position when traveling. It is dangerous if the engine stops when the machine is traveling, because it becomes impossible to operate the steering.
Page 22: Precautions When Operating
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. TRAVELING ON SLOPES ‡ Traveling on slopes could result in the machine tipping over or slipping to the side. ‡ When traveling on slopes, keep the work equipment approximately 20 – 30 cm (8 – 12 in) above the ground.
Page 23 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES ‡ Do not let the machine touch overhead electric cables. Even going close to high-voltage cables can cause electric shock.
Page 24: Working On Loose Ground
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. WORKING ON LOOSE GROUND ‡ Do not operate the machine on soft ground. It is difficult to get the machine out again. ‡ Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse under the mass or vibration of your machine, it could fall or tip over and this could result in serious injury or death.
Page 25 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PRECAUTIONS IN COLD AREAS ‡ After completing operations, remove all water, snow, or mud stuck to the wiring harness, connector 1, switches, or sensors, and cover these parts. If the water freezes, it will cause malfunctions of the machine when it is next used, which may lead to unexpected accidents.
Page 26: Transportation
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. 7.3 TRANSPORTATION LOADING AND UNLOADING ‡ Loading and unloading the machine always involves potential hazards. EXTREME CAUTION SHOULD BE USED. ‡ Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road.
Page 27: Battery
¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.4 BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid, and batteries generate hydrogen gas, so mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions. ‡...
Page 28: Starting With Booster Cables
¤ WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause a fire, so always do as follows. ‡...
Page 29: Towing
‡ If your machine is towed by another machine, stop the engine and release the brake. Please contact your Komatsu distributor to have the brake released. ‡ NEVER allow a disabled machine to be towed on a slope. ‡ Do not use a kinked or frayed wire rope.
Page 30: Precautions For Maintenance
MAINTENANCE follow these safety precautions. 8.1 BEFORE CARRYING OUT MAINTENANCE NOTIFICATION OF FAILURE Carrying out maintenance not described in the Komatsu operation and maintenance manual may lead to unexpected failures. Please contact your Komatsu distributor for repairs. WARNING TAG ‡ ALWAYS attach the “DO NOT OPERATE” warning tag to the blade control lever in the operator’s cab to alert others that you are working on the machine.
Page 31 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip.
Page 32: Proper Tools
Hoses and other parts of the fuel, hydraulic, and brake system are critical parts for ensuring safety, so they must be replaced periodically. Replacement of safety critical parts requires skill, so please ask your Komatsu distributor to carry out replacement.
Page 33 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE USE OF LIGHTING ‡ When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion specifica- tions. If such lighting equipment is not used, there is danger of explosion. ‡...
Page 34: During Maintenance
¤ WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. 8.2 DURING MAINTENANCE PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer. Extra precaution should be used when grinding, welding, and using a sledge-hammer.
Page 35 ¤ WARNING: Failure to follow these safety precautions may lead to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE LOCKING INSPECTION COVERS When carrying out maintenance with the inspection cover open, lock it securely with a lock bar. If maintenance is carried out with the inspection cover open and not locked in position, it may close suddenly if knocked or blown by the wind, and may cause injury to the operator.
Page 36 ‡ Depending on the type of failure, please contact your Komatsu distributor for repairs. RULES TO FOLLOW WHEN ADDING FUEL OR OIL If any flame is brought close to fuel or oil, there is danger that it will catch fire, so always follow the precautions below.
Page 37 If it is difficult to locate the leakage, always please contact your Komatsu distributor for repairs. ‡ If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
Page 38: Waste Materials
¤ WARNING: For reasons of safety, always 8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE Immediately after stopping operations, the engine coolant, oil at all parts, the exhaust manifold, and the muffler are at high temperature. In this condition, if the cap is removed, or the oil is drained, or the filters are replaced, this may result in burns or other injury.
Page 39: Position For Attaching Safety Labels
There are other labels in addition to the safety labels listed as follows, so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Komatsu distributor. 9.1 POSITION FOR ATTACHING SAFETY LABELS 1-29...
Page 40 SAFETY LOCK LEVER (located right of seat) Keep manual in machine cab to LOCK position. near operator. Sudden and unwanted machine Contact Komatsu distributor movement can cause serious for a replacement manual. injury or death. 09651-03001 09654-33001 2. Warning before moving in reverse 4.
Page 41 TOR’S BACK AGAINST SEAT BACK. 2. When loosening track shoe, if it does not loosen after ‡ AFTER ADJUSTING THE HEIGHT, turning plug A ONE TURN, ask Komatsu dealer or distribu- tor to disassemble. FORE AND AFT POSITIONS OF THE 3.
Page 42: Content And Use Of Warning Plates
COMPLY WITH THE FOLLOWING REQUIREMENTS: a) ISO 3471 (ROPS) & ISO 3449 (FOPS) b) SAE J & SAE J • Altering ROPS may weaken it. Consult Komatsu Distributor before altering.  • ROPS may provide less protection if it has been structurally dam- WARNING aged or involved in roll-over.
Page 43: Operation
OPERATION...
Page 44: General View
10. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, they refer to the directions shown by the arrows in the diagram below. 1. Blade 6. Sprocket 2. Blade lift cylinder 7. Track frame 3. Cab 8.
Page 45: General View Of Controls And Gauges
10. GENERAL VIEW 10.2 GENERAL VIEW OF CONTROLS AND GAUGES...
Page 46: Explanation Of Components
11. EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is impor- tant to understand fully the methods of operating the equipment and the meanings of the displays. Before reading the explanation of components, please read the table below to check what equipment is installed to your machine.
Page 47 11. EXPLANATION OF COMPONENTS 2. ENGINE WATER TEMPERATURE GAUGE White This gauge 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.
Page 48 11. EXPLANATION OF COMPONENTS 6. CHARGE MONITOR This monitor indicates an abnormality in the charging system while the engine is running. If the monitor lamp flashes, stop the engine and check the V-belt tension. If any abnormality is found, see “16. TROUBLESHOOTING.” REMARK This monitor lamp lights, when the starting switch is turned to AD051618...
Page 49 11. EXPLANATION OF COMPONENTS 10. MONITOR CAUTION LAMP If any of caution lamps 5, 6, 7 or 9 light up, the monitor caution lamp lights up. In addition, the alarm buzzer sounds at the same time. AD05161C 11. MONITOR CAUTION CANCEL SWITCH This switch is used to cancel monitor caution lamp 0.
Page 50: Switches
11. EXPLANATION OF COMPONENTS 11.1.2 SWITCHES 1. STARTING SWITCH This switch is used to start the engine. Key insertion-withdrawal position. None of electrical circuits activate. START Charging and electric device circuits activate. Keep key at ON after starting. START At this key position, the starting motor will crank the engine. Immediately after starting the engine, release the key which will automatically return to the ON position.
Page 51 11. EXPLANATION OF COMPONENTS 2. FRONT LAMP, WORKING LAMP SWITCH This lights up the front lamps, working lamps at the front of the left and right fenders, and the panel lamp. OFF position: Lamps are out ON position: Lamps light up 3.
Page 52 11. EXPLANATION OF COMPONENTS 11.1.3 LAMP 1. AIR CLEANER CLOGGING CAUTION LAMP This warns the operator that the air cleaner element is clogged. The lamp should be OFF during normal operation. If the lamp lights up during operation, replace the element immedi- ately.
Page 53: Horn Switch
11. EXPLANATION OF COMPONENTS 11.2 SWITCHES 1. HORN SWITCH The horn sounds when the button at the rear of the blade control lever at the right side of the operator’s seat is pressed. 2. ROOM LAMP SWITCH (MACHINES EQUIPPED WITH CAB) This lights up the room lamp.
Page 54: Wiper Switch
11. EXPLANATION OF COMPONENTS 3. WIPER SWITCH This activates the wipers. The wiper switches are as follows. A Left door B Front window C Right door D Rear window 4. CIGARETTE LIGHTER This is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after a few seconds, so take it out to light your cigarette.
Page 55: Control Levers And Pedals
11. EXPLANATION OF COMPONENTS 11.3 CONTROL LEVERS AND PEDALS 1. FUEL CONTROL LEVER This lever 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 position a until you feel the operating force falls off.
Page 56 11. EXPLANATION OF COMPONENTS 2. JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER) This is used to select the direction of travel, to carry out steering, and to carry out counterrotation turns. Forward-reverse shifting a: FORWARD b: REVERSE N: NEUTRAL Push the lever forward, the machine will move off forward. Pull the lever backward, the machine will move off in reverse.
Page 57: Brake Pedal
11. EXPLANATION OF COMPONENTS 3. BRAKE PEDAL  WARNING Do not place your foot on this pedal unnecessarily. Depress the pedal to apply the right and left brakes. 4. DECELERATION PEDAL  WARNING ‡ Do not place your foot on this pedal unnecessarily. ‡...
Page 58 11. EXPLANATION OF COMPONENTS 6. SAFETY LEVER (FOR BLADE CONTROL LEVER, RIPPER CONTROL LEVER)  WARNING ‡ When standing up from the operator’s seat, always set the safety 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.
Page 59: Blade Control Lever
11. EXPLANATION OF COMPONENTS 7. BLADE CONTROL LEVER (POWER TILTDOZER) This lever is used to raise or tilt the blade. Lifting control a RAISE : ( 2 ) b HOLD : ( w ) Blade is stopped and held in this position. c LOWER : ( s ) d FLOAT : ( x ) Blade will move freely according to external force.
Page 60 11. EXPLANATION OF COMPONENTS ‡ DUAL TILT OPERATION C + A: Left dual tilt (keep button C pressed and operate in direction A.) C + A: Right tilt (keep button C pressed and operate in direction If the tilt operation is carried out with button C at the top center of the knob kept pressed, a larger tilting force can be obtained than in normal tilt operations.
Page 61 11. EXPLANATION OF COMPONENTS 8. RIPPER CONTROL LEVER (FOR VARIABLE RIPPER) This is used to operate the ripper. a RAISE ( r ) b HOLD ( f ): Ripper is stopped and held in the same position. c LOWER( v ) A Digging angle reduced ( 5 ) : Cutting angle (α) becomes smaller.
Page 62: Dust Indicator
11. EXPLANATION OF COMPONENTS 11.4 DUST INDICATOR This device indicates clogging of the air cleaner element. When the red piston appears in transparent part 1 of this indicator, the element is clogged. Clean the element immediately. After cleaning, push indicator button 2 to return the red piston to its original position.
Page 63 11. EXPLANATION OF COMPONENTS 11.6.1 FUSE CAPACITY AND CIRCUIT NAME Fuse box I Fuse capacity Circuit 20 A Starting switch 20 A Car stereo, cigarette lighter, room lamp – – – – – – – – 20 A Spare power source 20 A Spare power source –...
Page 64: Door-Open Lock
11. EXPLANATION OF COMPONENTS 11.7 DOOR-OPEN LOCK Use this when your want to keep the door held open. 1. Push the door against door catch 1. The door will be held by the door catch. 2. To release the door, move lever 2 inside the cab to the front of the cab.
Page 65: Tool Box
11. EXPLANATION OF COMPONENTS 11.11 TOOL BOX This is inside the cover at the left of the machine. It is used for storing tools. 11.12 HANDLING ADDITIONAL HEATER If more powerful heating is required during cold weather, use an additional heater. Control switch 1 also acts to regulate the air flow.
Page 66: Handling Air Conditioner
11. EXPLANATION OF COMPONENTS 11.13 HANDLING AIR CONDITIONER 11.13.1 GENERAL LOCATIONS OF CONTROL PANEL 1 Vent selector lever 5 Air conditioner switch 2 FRESH/RECIRC selector switch 6 OFF switch 3 Temperature control switch 7 Defroster selector lever 4 Air flow selector switch VENT SELECTOR SWITCH (sending air to upper half of cab) If lever 1 is pulled to position b, the air from the air conditioner is all directed to the upper half of the cab.
Page 67 11. EXPLANATION OF COMPONENTS VENT SELECTOR SWITCH (sending air to feet) If lever 1 is pushed to position a, the air from the air conditioner is all directed to the feet. This can be used to send warm air to the feet during cold weather.
Page 68 11. EXPLANATION OF COMPONENTS AIR FLOW SELECTOR SWITCH (LO) Switch 4 is used to set the flow of air from the air conditioner to LOW. When this switch is pressed, the air flow is set to the minimum amount of the three available levels. AIR FLOW SELECTOR SWITCH (MID) Switch 4 is used to set the flow of air from the air conditioner to MID (medium).
Page 69 11. EXPLANATION OF COMPONENTS 11.13.2 PRECAUTIONS WHEN USING AIR CONDITIONER CARRY OUT VENTILATION FROM TIME TO TIME WHEN USING THE COOLER. ‡ If you smoke when 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.
Page 70: Cleaning Air Filter
11. EXPLANATION OF COMPONENTS 11.13.4 PROCEDURE FOR REPLACING RECEIVER Replace the receiver every two years. After replacing the receiver, add compressor oil. When adding oil, place the receiver at an angle and measure the amount of oil remaining inside the receiver. Add the same amount of fresh oil (Densoil 6) to the receiver.
Page 71: Handling Accumulator
‡ Do not weld any boss to the accumulator. ‡ When disposing of 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 operated for a short time even after the engine is stopped.
Page 72: Reversing Reversible Fan
11. EXPLANATION OF COMPONENTS 11.15 REVERSING REVERSIBLE FAN When reversing the reversible fan in cold weather, do as follows. 1. Loosen bolt 2, then remove cover 1 on the right side of the radiator guard. A hole for inserting the tool can be seen. 2.
Page 73: Handling Engine Side Cover, Engine Room Quilting
11. EXPLANATION OF COMPONENTS 11.16 HANDLING ENGINE SIDE COVER, ENGINE ROOM QUILTING (if equipped) Install and remove the engine side covers and engine room quilting as shown in the chart below. Ambient temperature –50 –40 –30 –20 –10 30 40°C Install Side covers Remove...
Page 74: Operation
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.
Page 75 12. OPERATION 5. Check the undercarriage (track, sprocket, idler, guard) for dam- age, wear, loose bolts, or leakage of oil from rollers If any damage, wear, or oil leakage is found, repair the problem and tighten the bolts. 6. Check for damage to handrail, loose bolts Repair any damage and tighten any loose.
Page 76: Check Before Starting
2 seconds. REMARK If the lamps do not light up, there may be a failure or disconnec- tion in the monitor, so please contact your Komatsu distributor. NOTICE When carrying out the checks before starting, do not relay only START on the monitor.
Page 77 12. OPERATION CHECK FUEL LEVEL, ADD FUEL ¤ WARNING When adding fuel, never let the fuel overflow. This may cause a fire. 1. Turn the engine starting switch to the ON position and check the fuel level with fuel level gauge G on the monitor panel. After checking, turn the switch back to the OFF position.
Page 78 12. OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the engine side cover on the right side of the chassis. 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.
Page 79 12. OPERATION CHECK OIL LEVEL IN POWER TRAIN CASE (INCL. TRANSMISSION, TORQUE CONVERTER AND BEVEL GEAR CASES), ADD OIL 1. Start the engine and run at idling for 5 minutes, then check the oil level with the COLD side of dipstick G. 2.
Page 80 12. OPERATION CHECK DAMPER CASE OIL LEVEL, ADD OIL 1. Remove dipstick G, and wipe the oil off with a cloth. 2. Insert dipstick G fully into the dipstick holder, then pull it out again. 3. The oil level should be between the H and L marks on dipstick If the oil is below the L mark, add engine oil through the dipstick holder.
Page 81: Check Oil Level In Hydraulic Tank, Add Oil
12. OPERATION CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL  WARNING ‡ When removing the oil filler cap, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap.
Page 82 When carrying out walk-around checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. 2-40...
Page 83 3. Turn the rear lamp switch to the ON position and check that the rear lamps on the left and right fenders light up. 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. CHECK HORN SOUND 1.
Page 84 12. OPERATION CHECK BACKUP ALARM SOUND 1. Turn the key of starting switch to the ON position. START 2. Set the joystick to the REVERSE position. The buzzer must sound immediately. The buzzer will continue to sound until the joystick is moved to the NEUTRAL or FORWARD position.
Page 85 12. OPERATION 12.1.3 ADJUSTMENT BEFORE STARTING OPERATION 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.
Page 86 12. OPERATION ADJUST MIRROR Loosen nut 1 of the mirror and adjust the mirror to a position where it gives the best view from the operator’s seat. In particular, be sure to adjust the mirror so that people at the rear left or right of the machine can be seen clearly.
Page 87 12. OPERATION 12.1.4 ADJUST STEERING, DIRECTIONAL, SPEED LEVER (WRIST CONTROL TYPE SINGLE LEVER :JOYSTICK) The steering, directional, and speed lever (wrist control type single lever :joystick) can be adjusted by 100 mm in 5 stages to the front or rear. Adjust to the most suitable position to match the adjustment of the operator’s seat.
Page 88: Operations And Checks Before Starting Engine
12. OPERATION 12.1.5 OPERATIONS AND CHECKS BEFORE STARTING ENGINE  WARNING If the work equipment control levers are touched by accident, the work equipment may move suddenly. When leaving the operator’s compartment, always set the safety lever securely to the LOCK position. 1.
Page 89 12. OPERATION 4. Check that the ripper is lowered to the ground. 5. Check that safety lever 4 is locked. If safety lever 4 is locked, the blade control lever is returned to the HOLD position even if it is at the FLOAT position. 2-47...
Page 90: Starting Engine
12. OPERATION 12.2 STARTING ENGINE 12.2.1 NORMAL STARTING ¤ WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 91: Starting In Cold Weather
12. OPERATION 12.2.2 STARTING IN COLD WEATHER (Starting with APS (Automatic Priming System)) When starting in low temperatures, do as follows. ¤ WARNING ‡ Never use starting aid fluids as they may cause explosions. ‡ Check that there is no person or obstacle in the surrounding area, then sound the horn before starting.
Page 92 12. OPERATION 6. When preheating switch 4 is turned ON, preheating pilot lamp 5 will also light up, and preheating will automatically start. 7. Keep in this condition until preheating pilot lamp 5 goes out. (Preheating is completed after approx. 12 seconds, and the lamp goes out.) 8.
Page 93 12. OPERATION REMARK ‡ The time which should elapse before turning the preheating switch off varies with the ambient temperature. Confirm the time to the table below. Time from the starting of engine Ambient temperature until turning off the preheater switch 15 –...
Page 94: Operations And Checks After Starting Engine
12. OPERATION 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE After starting the engine, do not immediately start operations. First, carry out the following operations and checks. NOTICE ‡ Avoid abrupt acceleration until warm-up run is completed. ‡ Do not run the engine at low idling or high idling for more than 20 minutes.
Page 95 12. OPERATION 12.3.2 IN COLD AREAS 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 10 minutes with no load (warm-up run). 2. Operate blade control lever 3 to the RAISE position, then keep the blade raised to the maximum height and continue to relieve the circuit for 10 minutes.
Page 96: Moving Machine
12. OPERATION 12.4 MOVING MACHINE  WARNING ‡ When moving machine, check that the area around the ma- chine is safe, and sound the horn before moving. Clear all personnel from the machine and the area. Clear all obstacles from the path of the machine. Use extreme care when reversing the machine.
Page 97 12. OPERATION 5. Pull fuel control lever 7, raise the engine speed, and fully depress decelerator pedal 8. 6. Move joystick 3 to the F (FORWARD) or R (REVERSE) position, gradually release decelerator pedal 8 and allow the machine to move off.
Page 98: Shifting Gear
12. OPERATION 12.5 SHIFTING GEAR It is possible to change the speed range when traveling, so there is no need to stop the machine when shifting gear. 1. Move joystick 1 to the desired gear position to shift gears. Gear shifting Rotate the joystick 30°...
Page 99: Shifting Between Forward And Reverse
12. OPERATION 12.6 SHIFTING BETWEEN FORWARD AND REVERSE  WARNING When switching between FORWARD and REVERSE, check first that the direction of travel is safe.  CAUTION There is no need to stop the machine even when switching between FORWARD and REVERSE. To increase safety, operator comfort, and the life of the trans- mission, leave the engine running at full speed, and always depress the decelerator pedal to lower the engine speed.
Page 100: Steering Machine
12. OPERATION 12.7 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 make a pivot turn at high speed. 12.7.1 NORMAL TURNING To turn the machine while traveling, incline joystick 1 in the direction to turn.
Page 101 12. OPERATION 12.7.2 TURNING WHILE DESCENDING A SLOPE  WARNING ‡ On steep downhill slopes where the machine may travel under its own weight, or on downhill slopes where it is being pushed by a towed machine, the machine will steer in the opposite direction, so do as follows.
Page 102: Stopping Machine
12. OPERATION 12.8 STOPPING 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.
Page 103: Precautions For Operation
12. OPERATION 12.9 PRECAUTIONS FOR OPERATION 12.9.1 PAY ATTENTION TO GAUGES When the red range lights on the power train oil temperature gauge while operating, reduce load and wait for lowering of tem- perature. 12.9.2 METHOD OF USING STEERING CLUTCH If the steering clutch one side is used frequently or if many gradual turns are made with steering clutch half-engaged, the steer- ing clutch will wear out in a short time.
Page 104 12. OPERATION 12.9.5 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.
Page 105: Work Possible Using Bulldozer
12. OPERATION 12.10 WORK POSSIBLE USING BULLDOZER In addition to the following, it is possible to further increase the range of applications by using various attachments. 12.10.1 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.
Page 106 12. OPERATION 12.10.5 SMOOTHING NOTICE Avoid smoothing on rocky or stony ground. It can damage the blade. When finishing the ground surface to a smooth finish after digging or filling operations, keep a full load of soil in the blade and operate the blade up or down in small movements while traveling forward.
Page 107: Ripper Operation
12. OPERATION 12.11 RIPPER OPERATION 12.11.1 METHOD OF OPERATING PIN PULLER This is used only on machines equipped with a giant ripper. 1. Stop the machine in a safe place and lower the shank to the ground. 2. Operate the pin puller controller switch to the PULL OUT position and remove the mounting pin.
Page 108: Adjustment Of Work Equipment
12. OPERATION 12.12 ADJUSTMENT OF WORK EQUIPMENT ¤ WARNING When adjusting, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine and lock the work equipment securely with the safety lock.
Page 109: Shim Adjustment
12. OPERATION ADJUSTING BRACE ¤ WARNING If maintenance is carried out with the engine running, always have one worker sitting in the operator‘s seat while another worker carries out the maintenance. Both workers must mutu- ally confirm the safety during the operation. Start the engine and use inching control to tilt to the left and right.
Page 110 12. OPERATION 12.12.2 ADJUSTING RIPPER ADJUSTING DIGGING DEPTH Mounting pin holes are provided in the shank and these are used according to the desired digging depth. For normal use, use the bottom hole, and when particularly deep digging is needed, use the top hole.
Page 111: Parking Machine
12. OPERATION 12.13 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.
Page 112: Check After Finishing Work
12. OPERATION 4. Operate blade control lever 5 and ripper control lever 6 to the LOWER position, and lower the blade and ripper to the ground. 5. Set blade control lever 5 and ripper control lever 6 to the HOLD position.
Page 113: Stopping Engine
12. OPERATION 12.15 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 low speed to allow it to cool gradually, then stop it.
Page 114: Locking
12. OPERATION 12.17 LOCKING To prevent vandalism, there are locks at the following places. Places that can be locked with the starting switch key. Right and left engine side cover 1 (left side: 3 places, right side: ‡ 2 places) ‡...
Page 115: Operation Method
12.18.1 OPERATION METHOD ‡ Select the track shoe that best suits the type of soil to be encountered in service. Please consult your Komatsu distributor when selecting track shoes. ‡ Do not allow shoe slipping to occur during operation. If shoe slipping occurs, reduce load to the blade until slipping stops.
Page 116: Inspection And Adjustment
The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Perform periodical inspection and contact the Komatsu distributor in your area when machine has approached repairable limits and reversing limits. MEASURING HEIGHT OF GROUSER After taking up slack in track shoes, measure height at center of shoe as shown below.
Page 117: Transportation
13. TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. 13.1 LOADING, UNLOADING WORK ¤ WARNING ‡ Make sure the ramp has sufficient width, length and thick- ness to enable the machine to be safely loaded and unloaded. If the ramp sags appreciably, reinforce it with blocks, etc.
Page 118: Precautions For Loading
This description of the method for lifting the chassis applies to standard specification machines. Depending on the attachments and options installed, the method of lifting will differ. In such cases, please contact your Komatsu distributor for advice. For details of the weight, see “25. SPECIFICATIONS”.
Page 119: Precautions For Transportation
13. TRANSPORTATION 13.4 PRECAUTIONS FOR TRANSPORTATION  WARNING Determine the route for transporting the machine by taking into account the width, height and weight of the machine. Obey all state and local laws governing the weight, width and length of a load. Observe all regulations governing wide loads. 13.5 REMOVAL OF CAB (MACHINES EQUIPPED WITH CAB) If it is necessary to remove the cab for transportation, disconnect...
Page 120: Installation Of Cab (Machines Equipped With Cab)
13. TRANSPORTATION 13.6 INSTALLATION OF CAB (MACHINES EQUIPPED WITH CAB) Install the cab parts in the opposite order to removal. Connect all parts that were disconnected. Install the cab mounting bolts as follows. 1. Lower the cab slowly on top of the floor frame. 2.
Page 121: Cold Weather Operation
14. COLD WEATHER OPERATION 14.1 PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows. 14.1.1 FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see “20.
Page 122 14. COLD WEATHER OPERATION 14.1.3 BATTERY ¤ WARNING ‡ To avoid gas explosions, 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.
Page 123: After Completion Of Work
14. COLD WEATHER OPERATION 14.2 AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions. ‡ Mud and water on the machine body should be completely removed.
Page 124: Long-Term Storage
15. LONG-TERM STORAGE 15.1 BEFORE STORAGE When putting the machine in storage for more than one month, do as follows. ‡ After washing and drying each part, store the machine indoors. If it has to be left outdoors, choose a flat place where the machine will be safe from flooding or other problems, and cover the machine.
Page 125: After Storage
15. LONG-TERM STORAGE 15.3 AFTER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service. Carry out the following procedure when taking the machine out of long-term storage. ‡...
Page 126: Troubleshooting
16. TROUBLESHOOTING 16.1 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 “24.5 EVERY 500 HOURS SERVICE”. 16.2 METHOD OF TOWING MACHINE ¤...
Page 127: Starting Engine With Booster Cable
16. TROUBLESHOOTING 16.3.1 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: REMOVAL, INSTALLATION OF BATTERY CABLE 1. Open battery cover 1. 2. Before removing the battery, remove the ground cable (normally connected to the negative - terminal). If any tool touches between the positive terminal and the chassis, there is danger of sparks being generated.
Page 128: Starting The Engine
16. TROUBLESHOOTING CONNECTING THE BOOSTER CABLES Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the num- bers marked in the diagram. 1. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.
Page 129: Other Trouble
16.4 OTHER TROUBLE ‡ ): 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. 16.4.1 ELECTRICAL SYSTEM Problem Main causes...
Page 130 16. TROUBLESHOOTING 16.4.2 CHASSIS Problem Main causes Remedy Oil pressure in torque converter ‡ Improper tightening of oil pipe, ‡ Check, repair fails to rise pipe joint, air leaking in or oil leaking out because of damage ‡ Wear, scuffing of gear pump (‡...
Page 131 16. TROUBLESHOOTING 16.4.3 ENGINE Problem Main causes Remedy Engine oil pressure monitor ‡ Engine oil pan oil level is low ‡ Add oil to specified level, see CHECK flashes when engine speed is (sucking in air) BEFORE STARTING raised after completion of warm- ‡...
Page 132 16. TROUBLESHOOTING 16.4.3 ENGINE Problem Main causes Remedy Engine oil pressure monitor ‡ Engine oil pan oil level is low ‡ Add oil to specified level, see CHECK flashes when engine speed is (sucking in air) BEFORE STARTING raised after completion of warm- ‡...
Page 133 16. TROUBLESHOOTING 16.4.4 APS (Automatic Priming System) Problem Main causes Remedy Engine does not start at all. ‡ Nozzle clogging (dust, paraffin (‡ Clean, change to specified fuel, precipitation, defective nozzle) replace nozzle) ‡ Defective glow plug (‡ Replace) ‡ Fuel pipe collapse, fuel leak, (‡...
Page 134: Maintenance
MAINTENANCE...
Page 135: Guides To Maintenance
Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the parts list as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Always use clean washer fluid: Use automobile window washer fluid and be careful not to let any dirt get into it.
Page 136 Never spray steam or water directly at the radiator or oil cooler portions. Controller: The machine monitor controller may malfunction if affected by electrical interference from an outside source, so when installing any radio system to the machine, please contact your Komatsu distributor for advice. Checking lubricating oil level: The lubricating oil level should be neither too high nor too low.
Page 137 17. GUIDES TO MAINTENANCE Avoid mixing oils: Never mix oils of different brands. If you have only oil which is a different brand from the one that is used in the machine, do not add it but replace all the oil. Bleeding air: After changing the oil, or replacing or cleaning the filter element or strainer, bleed the air from inside the circuit.
Page 138: Outlines Of Service
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.
Page 139 When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. ‡ Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
Page 140: Storing Oil And Fuel
Never remove or disassemble any electric components installed in the machine. ‡ Never install any electric components other than these specified by Komatsu. ‡ Be careful to keep the electric system free of water when washing the machine or when it rains.
Page 141: Outline Of Hydraulic System
18. OUTLINES OF SERVICE 18.3 OUTLINE OF HYDRAULIC SYSTEM ‡ During operation and immediately after operation is ended, the temperature of the hydraulic system still remains high. In addition, high hydraulic pressure is applied to the system. Take care when inspecting and maintaining the hydraulic system.
Page 142: Wear Parts List
The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. The parts in parentheses are to be replaced at the same time.
Page 143 19. WEAR PARTS LIST Weight Replacement Item Part No. Part Name Q’ty (kg) frequency 195-78-71111 Protector – Multi 195-78-71320 Point 26.0 – (195-78-71360) (Pin) – Ripper 195-78-71111 Protector – Giant 195-78-71320 Point 26.0 – (195-78-71360) (Pin) – NOTICE When handling parts that weight more than 25 kg (55 lb), remember that they are heavy objects, and take the necessary care.
Page 144: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPERATURE CAPACITY KIND OF RESERVOIR –40 –22 –4 68 86°F FLUID Specified Refill –40 –30 –20 –10 20 30°C amount capacity SAE 15W-40 SAE 10W-30 58 ¬...
Page 145 ‡ We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping.
Page 146: Standard Tightening Torques For Bolts And Nuts
175-900-3910 Reversible fan If any of the above tools are broken, please order them from your Komatsu distributor. When not using the tools, always put them in the tool box on the inside of the fender cover on the right side of the machine.
Page 147: Torque List
The tightening torque is determined by the width across the flats b 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.
Page 148: Periodic Replacement Of Safety Critical Parts
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the critical parts. 3-15...
Page 149 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q’ty Replacement interval Fuel hose (between nozzles) Turbocharger lubricating hose Fuel hose (nozzle – fuel return hose) Fuel hose for APS Fuel hose (fuel filter – injection pump) Fuel hose (feed pump –...
Page 150 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q’ty Replacement interval Hose (PPC valve for blade – PPC drain relay block) Hose (PPC valve for ripper – main valve) Hose (PPC valve for ripper – PPC drain relay block) Hose (PPC charge valve –...
Page 151: Maintenance Schedule Chart
23. MAINTENANCE SCHEDULE CHART 23.1 MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 250 HOURS SERVICE (only after the first 250 hours) Replace fuel filter cartridge 3-53 Replace transmission filter element and torque converter oil filter element 3-54 Change oil in power train case, clean strainer (incl. transmission case, torque 3-57 converter case and bevel gear case) Change oil in hydraulic tank, replace hydraulic oil filter element...
Page 152 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE (WHEN REQUIRED) Lubricating 3-42 ‡ Fuel control lever shaft (5 places) 3-42 ‡ Steering brake control lever shaft (18 places) 3-42 ‡ Universal joint (2 places) 3-43 Drain water and sediment in water separator 3-43 CHECK BEFORE STARTING Check machine monitor...
Page 153 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE (EVERY 250 HOURS SERVICE) ‡ Ripper arm pin (front) (2 places) 3-45 ‡ Ripper arm pin (rear) (2 places) 3-45 ‡ Equalizer bar side shaft (2 places) 3-46 ‡ Suspension (Equalizer bar center shaft) (1 place) 3-46 ‡...
Page 154: Service Item
23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE (EVERY 2000 HOURS SERVICE) Clean, check turbocharger 3-65 Check play of turbocharger rotor 3-65 Check alternator, starting motor 3-65 Check engine valve clearance, adjust 3-65 EVERY 4000 HOURS SERVICE Check water pump 3-66 Check vibration damper 3-66 Check fan pully and tension pulley...
Page 155: Service Procedure
24. SERVICE PROCEDURE 24.1 INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours. ‡ REPLACE FUEL FILTER CARTRIDGE ‡ REPLACE TRANSMISSION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT ‡ CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINER (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE) ‡...
Page 156: When Required
24. SERVICE PROCEDURE 24.2 WHEN REQUIRED 24.2.1 CLEAN INSIDE OF COOLING SYSTEM ¤ WARNING ‡ Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine to cool before draining water. ‡ Never be under the machine with the engine running. To avoid serious injury, always stop the engine before being under the machine to open the drain valve.
Page 157 ‡ We recommend use of an antifreeze density gauge to control the mixing proportions. ‡ Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. 3-24...
Page 158 24. SERVICE PROCEDURE 1. Stop the engine and tighten valve 1 of the corrosion resistor. 2. Turn radiator cap 2 slowly and remove it. 3. Set a container to catch the coolant, open drain valve 3 at the bottom of the radiator and drain valve 4 at the bottom of oil cooler and drain plugs 5 at the both sides of cylinder block, and drain off the cooling water.
Page 159 24. SERVICE PROCEDURE 14. Stop the engine, wait for 3 minutes, add city water until the water level reaches near the water filler port, then tighten the cap 2. 15. Open the cap of subtank 6 and add water into the subtank referring to the section “24.3 CHECK BEFORE STARTING”.
Page 160 24. SERVICE PROCEDURE 24.2.2 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ¤ WARNING ‡ Never clean or replace the air cleaner element with the engine running. ‡ When using pressure air to clean the element wear safety glasses or goggles to protect the eyes. CHECK If the red piston can be seen in transparent portion of dust indicator 1, clean the air cleaner element.
Page 161 24. SERVICE PROCEDURE REPLACING INNER ELEMENT 1. First remove the outer element, and then remove the inner element. 2. To prevent dust from getting in, use a clean cloth or tape to cover the air connector (outlet side). 3. Clean the air cleaner body interior, then remove the cover installed in Step 2.
Page 162 4. 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 1. First remove the bolt 1, and then remove the cover 2.
Page 163 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu dis- tributor. 1. Remove both bolts 1, then remove cover 2.
Page 164 Tighten the bolts in the order shown in the diagram on the right. 24.2.5 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. 3-31...
Page 165 24. SERVICE PROCEDURE 24.2.6 ADJUST IDLER CLEARANCE The idler moves forward and backward under external pressure. When this happens, side guide 1 and guide plate 2 become worn. As they become worn, there is side play in the idler, or the idler turns at an angle, causing the track to come off or resulting in uneven wear, so adjust as follows.
Page 166 24. SERVICE PROCEDURE 24.2.7 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 safety lever.
Page 167 24. SERVICE PROCEDURE 5. Install the edge to the blade, then tighten partially. Drop the blade three to five times on to the ground or rock to remove any play in bolt 2, then tighten it to the correct tightening torque. When installing end bit 3, put top surface 4 of the end bit in close contact with stopper 5, then tighten with the bolts.
Page 168 24. SERVICE PROCEDURE 24.2.8 CHECK AND CLEAN RADIATOR FIN ¤ WARNING When carrying out cleaning or inspection, always stop the engine and check that the fan is not rotating before starting. When the radiator fin block with mud, dirt or leaves, clean it as follows.
Page 169 If oil oozes out, the oil level has not gone down, so tighten the bolt. 2. If no oil comes out even when seal bolt 1 is removed, the oil level is low, so please contact your Komatsu distributor for repair. REMARK There is one bogie shaft seal bolt 1 each on the inside and outside.
Page 170 24. SERVICE PROCEDURE 24.2.13 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) If the air conditioner air filter is clogged or there is dirt or dust in it, clean the filter. 1. Open inspection cover 1 and remove fresh air filter 2. 2.
Page 171 24. SERVICE PROCEDURE 24.2.14 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. 6 kg (13.2 lb)) and check that the tension is 15 –...
Page 172 24. SERVICE PROCEDURE 24.2.17 REPLACE DOOR DAMPER Less than 2mm If the depth of the door damper rubber groove is less than 2 mm (0.08 in) (0.08 in), replace the damper. There are two dampers each at the top and bottom on the left and right doors.
Page 173 24. SERVICE PROCEDURE 24.2.19 REPLACE WIPER BLADE If the blade is damaged, it will not wipe the window clean, so replace the blade. Method of replacement Front wiper ‡ Front, rear wiper 1. Remove screw 1, then remove the blade. 2.
Page 174 13°C). If it is necessary to inspect the APS when the engine cooling water is above 13°C, so please contact your Komatsu distributor. 1. Open fuel valve 1 of the APS and remove hoses 2 of the nozzle inlet.
Page 175 24. SERVICE PROCEDURE 24.2.21 LUBRICATING 1. Lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3. After greasing, wipe off any old grease that was pushed out. 1.
Page 176 24. SERVICE PROCEDURE 3. Universal joint Apply grease to the grease fittings (2 places) shown by arrows.  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.
Page 177: Check Before Starting
24. SERVICE PROCEDURE 24.3 CHECK BEFORE STARTING For details of the following items, see “12.1.2 CHECK BEFORE STARTING” in the OPERATION section. ‡ Check machine monitor ‡ Check coolant level, add water ‡ Check fuel level, add fuel ‡ Check oil level in engine oil pan, add oil ‡...
Page 178: Every 250 Hours Service
24. SERVICE PROCEDURE 24.4 EVERY 250 HOURS SERVICE 24.4.1 LUBRICATING 1. Lower the work equipment to the ground, then stop the engine. 2. Using a grease pump, pump in grease through the grease fittings shown by arrows. 3. After greasing, wipe off any old grease that was pushed out. 1.
Page 179 24. SERVICE PROCEDURE 11. Equalizer bar side shaft (2 places) 12. Suspension (Equalizer bar center shaft) (1 place) Grease the suspension through the grease fittings marked by arrow. 1) Carry out greasing of the suspension (equalizer bar center shaft) through the grease fittings marked by arrows. 2) Pump the greasing lever up and down 3 –...
Page 180: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
(6.5 ± 1.5 kgm, 47 ± 11 lbft) 3. Check the drained oil, and if there are excessive metal particles of foreign material, please contact your Komatsu distributor. 4. Tighten drain valve 2. 5. Using a filter wrench, remove full-flow filter cartridge 3 by turning it counterclockwise.
Page 181 24. SERVICE PROCEDURE 7. When installing the filter cartridge, bring the packing surface into contact with the filter holder, then tighten a further 3/4 – 1 turn. 8. After replacing the filter cartridge, add engine oil through oil filler F until the oil level is between the H and L marks on the dipstick.
Page 182 24. SERVICE PROCEDURE 24.4.3 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ¤ WARNING ‡ When removing the oil filler cap, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap.
Page 183 24. SERVICE PROCEDURE 24.4.4 CHECK, ADJUST ALTERNATOR DRIVE BELT TENSION CHECK The standard deflection for the drive belt is approx. 15 mm (0.59 in) when pressed by thumb (approx. 6 kg (13.23 lb)) at a point midway between the drive pulley and alternator pulley. ADJUSTING Alternator pulley 1.
Page 184 24. SERVICE PROCEDURE 24.4.5 CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this check before operating the machine. ¤ WARNING ‡ To avoid gas explosions, 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.
Page 185 24.4.6 CHECK BRAKE PERFORMANCE ¤ WARNING If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately. Before starting the engine, check that the area around the machine is safe, then do as follows. 1. Start the engine.
Page 186: Every 500 Hours Service
24. SERVICE PROCEDURE 24.5 EVERY 500 HOURS SERVICE Maintenance for every 250 hours service should be carried out at the same time. 24.5.1 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.
Page 187 24. SERVICE PROCEDURE 9. Tighten air bleed plug 3, then push in the knob of feed pump 4 and tighten it. 10. After replacing the filter cartridge, start the engine and check that there is no leakage of oil from the filter seal surface. REMARK When only replacing the filter cartridge, it is enough to bleed the air from the air bleeding plug at the filter head.
Page 188 24. SERVICE PROCEDURE 24.5.3 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ¤ WARNING There is danger that the oil may spurt out under internal pressure, so to the side, and gradually turn the plug to release the internal pressure before removing the plug completely. 1.
Page 189 24. SERVICE PROCEDURE 24.5.4 CHECK, REPLACE FAN BELT Check the V-belt, and replace the V-belt if the condition is as follows. ‡ If the V-belt is in contact with the bottom of the pulley groove. ‡ If the V-belt is worn and has sunk below the outside diameter of the pulley.
Page 190: Every 1000 Hours Service
24. SERVICE PROCEDURE 24.6 EVERY 1000 HOURS SERVICE Maintenance for every 250 and 500 hours service should be carried out at the same time. 24.6.1 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE) ¤...
Page 191 24. SERVICE PROCEDURE 6. Take out strainer 5 and magnet 6. If any damage to strainer 5 or magnet 6 is found, replace with a new one. 7. Loosen bolt 7, then divide into strainer 5 and magnet 6. Tightening torque of bolt 7: 46 – 59 Nm (4.7 – 5.9 kgm, 34 – 43 lbft) 8.
Page 192 24. SERVICE PROCEDURE 24.6.3 CLEAN STEERING CLUTCH CASE BREATHER 1. Remove bolts 1, then remove cover 2. 2. Remove breather 3 on steering clutch case, and wash out dust remaining inside with diesel fuel or flushing oil. 24.6.4 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL 1.
Page 193: Replace Corrosion Resistor Cartridge
7. After replacing the cartridge, start the engine and check for any leakage of water from the filter seal surface. If there is any water leakage, check if the cartridge is tightened properly. 24.6.8 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor for inspection or adjustment. 3-60...
Page 194: Every 2000 Hours Service
24. SERVICE PROCEDURE 24.7 EVERY 2000 HOURS SERVICE Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time. 24.7.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT ¤ WARNING The oil is at high temperature immediately after the machine has been operated.
Page 195 24. SERVICE PROCEDURE 24.7.2 CHANGE OIL IN FINAL DRIVE CASE ¤ WARNING ‡ The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. ‡ There is danger that the internal pressure will cause the oil to spurt out, so when removing the plug, stand to the side and turn the plug slowly to release the internal pressure, then remove the plug carefully.
Page 196 24. SERVICE PROCEDURE 24.7.3 CHANGE OIL IN DAMPER CASE, CLEAN AIR HOLE AND BREATHER Prepare the following. ‡ Container to catch drained oil: Min. 2.1 ¬ capacity ‡ Refill capacity: 2.1 ¬ (0.55 US gal, 0.46 UK gal) 1. Remove breather 4 at the top of the damper. 2.
Page 197 24. SERVICE PROCEDURE 24.7.4 CHECK PIVOT BEARING OIL LEVEL, ADD OIL 1. Remove plug 1. When removing plug 1, be careful not to let dirt or dust get it. 2. Check that the oil is at the level shown in the diagram. If the oil level is low, add engine oil through the hole of plug 1.
Page 198: Check Engine Valve Clearance, Adjust
24.7.8 CHECK ALTERNATOR, STARTING MOTOR The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 199: Every 4000 Hours Service
24.8.1 CHECK WATER PUMP Check that there is oil leakage, water leakage, or clogging of drain hole 1. If any abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement. 24.8.2 CHECK VIBRATION DAMPER Check decrease of damper 1 fluid, dent or out-of-flat.
Page 200 Carefully check the base material of the steel casting and weld- ing at portions A – L, and check that there is no damage. If any cracks or other damage are found, carry out repairs. Please contact your Komatsu distributor for details of the repair procedure. Blade...
Page 201: Specifications
SPECIFICATIONS...
Page 202 32.5° and 55.5°) TOWING ‡ Towing force 48500 kg (475623 N) ENGINE ‡ Model Komatsu SA6D170E-2 diesel engine ‡ Flywheel horsepower 386 kW (525 HP)/1800 rpm ‡ Maximum torque 2648 Nm (270 kgm)/1300 rpm ‡ Starting motor 24 V 11 kW x 2 pieces ‡...
Page 203 25. SPECIFICATIONS Semi-U tilt dozer + variable multi ripper U tilt dozer + giant ripper...
Page 204: Options, Attachments
OPTIONS, ATTACHMENTS...
Page 205: General Precautions
26. GENERAL PRECAUTIONS 26.1 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, please contact your Komatsu distributor first.
Page 206: Using Seat Belt
27. USING SEAT BELT When operating a machine equipped with ROPS, be sure to use the seat belt. ¤ WARNING ‡ Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions. Replace any worn or damaged seat belt or the securing brackets.
Page 207 27. USING SEAT BELT REMARK If the lock is applied before the tongue is installed into the buckle, return the belt to the reel, then carry out the operation again from the beginning. 5. Tense the belt and check that the lock is applied. 6.
Page 208: Selection Of Track Shoe
28. SELECTION OF TRACK SHOE 28.1 SELECTION OF TRACK SHOES Select suitable track shoes to match the operating conditions. METHOD OF SELECTING SHOES If a wider shoe than necessary is used, the load on the track will increase, and this will cause the shoes to bend, links to crack, pins to break, shoe bolts to come loose, and various other problems.
Page 209: Procedure For Selecting Ripper Point
29. PROCEDURE FOR SELECTING RIPPER POINT 29.1 PROCEDURE FOR SELECTING RIPPER POINT...
Page 210: Handling Cap With Lock
30. HANDLING CAP WITH LOCK 30.1 OPENING AND CLOSING LOCKABLE CAP Lock-type caps are available for the radiator water filler cap, fuel tank filler cap, power train case oil filler cap, hydraulic tank oil filler cap, and hydraulic tank breather cap. The cap opening and closing method is as follows.
Page 211: Effective Method Of Operation For Dual Tilt
31. EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER 31.1 BLADE CONDITION Operating method Applicable operation Blade position Single tilt ‡ Normal operations ‡ Normal tilt operation Dual tilt ‡ Digging up boulders ‡ Turn the dual button ON ‡ Side cutting operations (high and carry out tilt operation places) ‡...
Page 212: Dozing Work
31. EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER 31.2 DOZING WORK 31.2.1 DOZING ON LEVEL GROUND OR DOWNHILL Natural ground, bedrock ¤ WARNING If you feel that the situation is dangerous when dumping the soil, for safety reasons, use two movements to push the soil over the edge.
Page 213 31. EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER Filling, soft soil Carry out digging in R pitch or S pitch, and haul in R pitch. REMARK If the digging is carried out in R pitch, there is no sudden digging into the soil, and the operation can be carried out smoothly.
Page 214 31. EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER 31.2.2 PUSHING-UP SOIL 1. Dig with S pitch When digging gradually, use R pitch. If the ground is hard, use F pitch. 2. Haul with R pitch. If there is any spillage of soil over the top of the blade, change to S pitch.
Page 215: Leveling (Spreading) Operations
31. EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER 31.3 LEVELING (SPREADING) OPERATIONS Carry out this operation with R pitch. When carry out this operation with R pitch, the end bit does not dig in, and the ground can be leveled (or the soil can be spread) smoothly.
Page 216: Horizontal Dozing Operations From Side Slope (Rough Ground)
31. EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER 31.7 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND) The dual tilt can give a larger amount of tilt, so when dozing from a side slope, this is effective because the chassis becomes horizontal after a short digging distance.

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