Operation & Maintenance Manual: Bulldozer

SEAM0071 02
Operation
& Maintenance
Manual
BULLDOZER
D65E-12 - 60948
SERIAL NUMBERS D65Pm12 - 60891 andup
D65E-12 - JlOOOl
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
August 1998 Copyright 1998 Komatsu America International Company

1. FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and
effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been
lost or has become dirty and can not be read, request a replacement manual from Komatsu or your
Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available
information of your machine or for questi.ons regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area.
Consult Komatsu or your Komatsu distributor for those items you may require.
A WARNING
Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in a readily available place near the machine (on machines with cab, there is
a door pocket to hold the manual), and have all personnel involved in working on the machine
read the manual periodically.
Where to keep this manual. - See “11.11 DOOR POCKET (MACHINES EQUIPPED WITH CAB)“.
Some actions involved in operation and maintenance of the machine can cause a serious accident,
If they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the machine.
if you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for you and others. In no event should you or others engage in prohibited
uses or actions as described in this manual.
Komatsu delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and specifications
that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor before operating the machine.
The description of safety is given in SAFETY INFORMATION on page O-2 and in SAFETY from page
l-l.
O-l
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and
maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings
in this manual and on the machine before performing operation and maintenance.
To identify safety messages in this manual and on machine labels, the following signal words are
used.
a
DANGER - This word is used on safety messages and safety labels where there is a high
probability of serious injury or death ff the hazard is not avoided. These sefety
messages or labels usually describe precautions that must be taken to avoid the
hazard. Failure to avoid this hazard may also result in serious damage to the
machine.
44
WARNING - This word is used on safety messages and safety labels where there is a
potentially dangerous situation which could result in serious injury or death if
the hazard is not avoided. These safety messages or labels usually describe
precautions that must be taken to avoid the hazard. Failure to avoid this hazard
may also result in serious damage to the machine.
CAUTION - This word is used on safety messages and safety labels for hazards which could
result in minor or moderate injury if the hazard is not avoided. This word might
also be word for hazards where the only result could be damage to the machine.
NOTICE - This word is used for precautions that must be taken to avoid actions which
could shorten the life of the machine.
Safety precautions are described in SAFETY from page l-l.

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact your
Komatsu distributor.
o-2
3. INTRODUCTION
3.1 INTENDED USE
This Komatsu BULLDOZER is designed to be used mainly for the following work:
l Dozing
l Smoothing
l Cutting into hard or frozen ground or ditching.
l Fellinn trees, removing stumps
See the section “12.15 WoRK PdSSlBLE USING BULLDOZER” for further details.
3.2 FEATURES
HIGH PRODUCTIVITY
l Powerful S6D125(6D125 for,D65E) engine and large-capacity blade provide high productivity.
l Low drive and long truck undercarriages are extraordinarily tough and offer excellent grading ability
and stability.
HIGH MANEUVERABILITY
l Wrist control type single-lever for steering/directional change makes operations smooth and easy.
l Wrist control type single-lever for blade control with PPC (Proportional Pressure Control) and CLSS
(Closed-center Load Sensing System) assures precise and responsive operation.
OPERATOR COMFORT
l Rubber-mounted power-train and valves substantially reduce noise and vibration.
l Pressurized cab with wide view and oil damper suspension offers a comfortable operating environment.
EASY MAINTENANCE AND HIGH DURABILITY

l Simple hull frame and monocoque track frames with pivot shafts assure greater reliability.
l Unique modular design facilitates the removal of power-train components.
l Larger-sized undercarriage components extend life.
3.3 BREAKING IN THE MACHINE
Your Komatsu machine has been thoroughly adjusted and tested before shipment.
However, operating the machine under severe conditions at the beginning can adversely affect the
performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.)
During breaking in:
l Idle the engine for 5 minutes after starting it up.
l Avoid operation with heavy loads or at high speeds.
l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of
emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only
those that apply when this product is used for the specified purpose. If the machine is used for a purpose
that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
o-3
4. LOCATION OF PLATES, TABLE TO ENTER *
SERIAL NO. AND DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION
This IS at the front bottom right of the operator’s seat.
4.2 ENGINE SERIAL NO. PLATE POSITION
This is in the center of the engine cylinder block on the right side
of the machine.
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

-----~~--.- ..._
--.- __., -
/-----
Machine serial No.:
i‘_-...-Engine serial
.~-__-.-
No.:
__----- -_- - .----.-
1
/ Distributor name:
I
I
Address: Phone:
Service personnel for your machine:
_-.--_..-_-- _- ____ _ _-___

--._
REMARKS
5. CONTENTS
1. Foreword ............................................................................................................................................ 0- 1
2. Safety information ............................................................................................................................ o- 2
3. introduction ........................................................................................................................................ o- 3
4. Location of plates, table to enter serial No. and distributor ...................................................... o- 4
SAFETY
6. General precautions ... . ... .. . .. . . .. .. . . .. .. .. . . .. . ... . .. .. . .. . .. . .. .. . . ... . . .. .. .. . .. . .. . . ... .. . .. .. . . . ... . . . ... . .. . .. . ... .. .. . .. . .. . .. . . .. .. I- 2
7. Precautions during operation .......................................................................................................... I- 9

7.1 Before starting engine ............................................................................................................. I- 9
7.2 Operating machine .................................................................................................................. I-II
7.3 Transportation .......................................................................................................................... 1-14
7.4 Battery ....................................................................................................................................... 1-15
‘7.5 Towing ...................................................................................................................................... 1-16
8. Precautions for maintenance ........................................................................................................... 1-17

8.1 Before carrying out maintenance .......................................................................................... 1-17
8.2 During maintenance ................................................................................................................ 1-19
9. Position for attaching safety labels ................................................................................................ l-24

9.1 Position for attaching safety labels ....................................................................................... l-24
OPERATION
10. General view . . .. . .. . .. .. .. . . .. .. . . ... .. . . . ... . . .. .. . .. .. .. .. . ... ... . .. .. . . .. . .. .. . .. .. . . .. .. .. . ... . . . .. .. . .. ... . . .. . .. . . .. .. . . .. .. . .. . .. . .. . ... .. . 2- 2
10 1 General view of machine ........................................................................................................ 2- 2
10.2 General view of controls and gauges ................................................................................... 2- 3
11. Explanation of components ............................................................................................................. 2- 6

1111 Front panel (meters, lamps, switches) .................................................................................. 2- 7
11.2 Switches. ................................................................................................................................... 2-20
11.3 Control levers, pedals .............................................................................................................. 2-23
11.4 Fuse box ................................................................................................................................... 2-30
11.5 Grease pump holder ............................................................................................................... 2-31
11.6 Shovel holder ........................................................................................................................... 2-31
17.7 Door-open lock (machines equipped with cab) ................................................................... 2-31
11.8 Sash glass intermediate lock (machines equipped with cab) ........................................... 2-32
1:.3 Cap with lock.. .......................................................................................................................... 2-32
11.10 Hot and cool box (machines equipped with cab) ................................................................ 2-33
?l.ll Door pocket !mach;rles equipped with cab) ......................................................................... 2-33
11.12 Ashtray (machines equipped with cab). ................................................................................ 2-33
'I".!3Tool hox ................................................................................................................................... 2-33
11.14 \Jsing car radio (machines equipped with cab, car radio) ................................................. 2-34
:I 15 Handling air conditioner (machines equipped with cab) .................................................... 2-38
11.16 Handlir?y heater (machines equipped with cab) .................................................................. 2-42
o-5 8
12. Operation . .. . .. . .. . .. .. .. . .. . .. . ... . . ... . . . ... .. . .. . .. . . ... .. . .. ... ... . . . .. .. .. . .. . .. . .. . .. .. .. . . .. .. . . . .. .. . .. ... . . . ... . . . .. .. . . .................... 2-43
1i.l Check before starting engine ................................................................................................. 2-43
12.2 Starting engine ......................................................................................................................... 2-52
12.3 Operations and checks after starting engine.. ...................................................................... 2-58
12.4 Moving machine ...................................................................................................................... 2-60
12.5 Shifting gear.. ........................................................................................................................... 2-61
12.6 Shifting between forward and reverse.. ................................................................................ 2-62
12.7 Steering machine ..................................................................................................................... 2-63
12.8 Stopping machine.. .................................................................................................................. 2-65
12.9 Precautions for operation ....................................................................................................... 2-66
12.10 Parking machine ...................................................................................................................... 2-68
12.11 Check after finishing work ...................................................................................................... 2-69
12.12 Stopping engine.. ..................................................................................................................... 2-70
12.13 Check after stopping engine.. ................................................................................................. 2-71
12.14 Locking ...................................................................................................................................... 2-71
12.15 Work possible using bulldozer ............................................................................................... 2-72
12.16 Adjusting posture of work equipment .................................................................................. 2-73
12.17 Tips for longer undercarriage life .......................................................................................... 2-76
13. Transportation .. .. . .. .. . .. .. . . .. .. .. .. .. .. . . .. .. . .. .. . . .. ... . . .. .. . .. . .. . .. . ... . .. .. .. .. .. .. .. . . .. .. .. .. ... . .. .. .. . .. .. . . .. .. . .. . ... . . ........... 2-79

13.1 Loading, unloading work ........................................................................................................ 2-79
13.2 Precautions for loading, and securing the machine.. .......................................................... 2-80
13.3 Precautions for transportation.. .............................................................................................. 2-81
13.4 Precautions when removing work equipment ..................................................................... 2-81
13.5 Removing cab (machines equipped with cab) ..................................................................... 2-81
13.6 Lifting the machine.. ................................................................................................................ 2-82
14. Cold weather operation .................................................................................................................... 2-85

14.1 Precautions for low temperature ........................................................................................... 2-85
14.2 After completion of work ........................................................................................................ 2-87
14.3 After cold weather ................................................................................................................... 2-87
15. Long-term storage ............................................................................................................................. 2-88

15.1 Before storage .......................................................................................................................... 2-88
15.2 During storage ......................................................................................................................... 2-88
15.3 After storage.. ........................................................................................................................... 2-88
16. Troubleshooting . ... .. .. .. . . .. .. . .. . .. .. . ... . .. . .. ... . .. . .. .. . .. .. . . .. .. .. . . .. .. . .. ... .. .. .. . . .. .. . .. . .. .. . .. . .. .. .. .. .. .. .. ... . . .. . .. . .......... 2-89

16.1 After running out of fuel ......................................................................................................... 2-89
16.2 If battery is discharged ........................................................................................................... 2-89
16.3 Other trouble ............................................................................................................................ 2-92
O-6
MAINTENANCE
17. Guides to maintenance . . .. . .. .. . . . .. .. .. .. . . .. . ... .. . .. . . .. . . .. .. . .. .. .. .. .. .. . .. .. .. . .. . .. . . .. . .. . .. . .. . .. .. . ... .. . . . .. .. . . .. .. .. .. .. . . .. . 3- 2
18. Outlines of service . . . .. . .. . . .. . .. . . .. . .. . . . ... .. . .. . .. . . .. . .. .. . . .. .. . . . .. .. . . . .. .. . .. . . .. .. . . .. .. . . .. .. . . . . ... . . .. .. . .. .. .. . .. . . .. .. . .. . . .. . . 3- 5

18.1 Outline of oil, fuel, coolant ..................................................................................................... 3- 5
18.2 Relating to electric system ..................................................................................................... 3- 7
19. Wear parts list . .. . . .. .. . .. .. . .. .. .. . .. . . . .. .. . . . .. .. . . .. .. . . . .. .. . . .. . .. . . . .. . ... . .. .. .. . . .. . .. . . .. .. . . .. .. . .. .. .. . .. . .. . .. . .. . .. . . .. . .. .. . . .. .. . 3- 8
20. Use of fuel, coolant and lubricants according to ambient temperature . .. .. . ... . . .. . .. . . .. .. . . .. . .. . . .. . . 3-10
21. Standard tightening torques for bolts and nuts ........................................................................... 3-14
21 .l Introduction of necessary tools.. ............................................................................................ 3-14
21.2 Torque list ................................................................................................................................. 3-15
22. Periodic replacement of safety critical parts .. .. . ... . . .. . . .. . .. . .. ... . .. .. .. . . ... . .. . . . ... .. . . .. .. . .. . . .. . . .. . . .. .. .. .. . . .. .. 3-16
23. Maintenance schedule chart . .. . .. .. .. . .. . . . .. . .. . . .. .. . .. .. .. . . .. . .. . .. . . .. .. . . . . ... . . .. .. . . . ... . . .. ... . . .. . . .. . .. . . . ... . . .. . . .. . .. .. .. 3-18
24. Service Procedure .. . . . .. .. . . . . .. . .. . . .. . .. . .. . . .. . . . .. .. . . . .. .. . . .. .. .. . .. . .. . . . ... . .. . .. ... . .. .. .. . . .. .. .. . .. . .. . .. . .. .. .. ... .. . .. .. .. . . . ... . . 3-21

24.1 When required ......................................................................................................................... 3-21
24.2 Check before starting .............................................................................................................. 3-40
24.3 Every 50 hours service ............................................................................................................ 3-44
24.4 Every 250 hours service .......................................................................................................... 3-45
24.5 Every 500 hours service .......................................................................................................... 3-55
24.6 Every 1000 hours service ........................................................................................................ 3-59
SPECIFICATIONS
25. Specifications . . .. .. .. . . . . .. .. .. . . .. .. .. .. .. . .. . . . ... . ... . .. .. . .. . .. .. .. . .. .. . .. .. . . . . ... . . .. . .. .. . .. . . .. .. . .. . . .. . .. . . . .. .. . . . .. .. .. .. .. .. . . . .. .. . 4- 2
o-7
5. CONTENTS
OPTIONS, ATTACHMENTS
26. General precautions ........................................................................................................................... 5- 2

26.1 Precautions related to safety.. ................................................................................................ 5- 2
27. Using seat belt ......................................................................................... .:. ...................................... 5- 3

27 1 Fasten the belt and remove it in the following manner.. ................................................... 5- 3
27.2 Adjust the belt length in the following manner .................................................................. 5- 4
28. Handling deluxe seat ......................................................................................................................... 5- 5
29. Handling accumulator ....................................................................................................................... 5- 7

29 1 Method of releasing pressure in operating circuit on machine equipped with
accumulator .............................................................................................................................. 5- 7
30. Equipping the fire extinguisher and the first-aid kit .................................................................... 5- 8
O-8
SAFETY
,- g WARNING
Read and follow all safety
result in serious injury or death.
This safety section also contains precautions for optional equip-

ment and attachments.
l-l
A bVf;;;bK&
E;eeasons ?f safety, always
6. GENERAL PRECAUTIONS y precautions.
SAFETY RULES
l ONLY trained and authorized personnel can operate and maintain the machine.
l Follow all safety rules, precautions and instructions when operating or performing maintenance
on the machine.
l When working with another operator or a person on worksite traffic duty, be sure all personnel
understand all hand signals that are to be used.
SAFETY FEATURES
Be sure all guards and covers are in their proper position. Have guards and covers repaired if
damaged.
Proper position - See “12.1.1 WALK-AROUND CHECK”.
Use safety features.such as the safety lock and seat belts properly.
NEVER remove any safety features. ALWAYS keep them in good operating condition.
Safety lever + See “12.10 PARKING MACHINE”.
Seat belts + See “27. USING SEAT BELT”.
Improper use of safety features could result in serious bodily injury or death.
CLOTHING AND PERSONAL PROTECTIVE ITEMS

Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts
and cause serious injury or death. Also, do not wear oily clothes because they are flammable.
Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the
machine. Always wear safety goggles, hard hat and heavy gloves if your job involves scattering
metal chips or minute materials -this is so particularly when driving pins with a hammer and when
cleaning the air cleaner element with compressed air.
Check also that there is no one near the machine.
Cleaning of air cleaner element + See “24.1 WHEN REQUIRED” in service procedure.
l-2
A E”,;;;zz; Fei;%ito follow these safety precautions may lead
6. GENERALPRECAUTIONS
UNAUTHORIZED MODIFICATION t
l Any modification made without authorization from Komatsu can create hazards.
l Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible
for any injury or damage caused by any unauthorized modification.
STANDING UP
To avoid hitting unlocked control levers, before standing up from operator’s seat, do the follwing:
Move steering and directional lever to neutral and move PARKING LEVER (located left of seat) to
LOCK position.
Lower work equipment to ground and move SAFETY LEVER (located right of seat) to LOCK
position.
Sudden and unwanted machine movement can cause serious injury or death.
l-3
A EJ3$;isze Fo;ereasons of safety, always
6. GENERAL PRECAUTIONS y precautions.
1 MOUNTING AND DISMOUNTING 1

NEVER jump on or off the machine. NEVER get on or off a moving machine.
When mounting and dismounting, face the machine and use the handholds and steps. Maintain
three-point contact to be sure that you do not fall from the machine.
Do not hold any control levers when getting on or off the machine.
Repair any damaged handhold or step, and tighten any loose bolts. Handholds and steps must
be free of oil, grease and excessive dirt.
When mounting or dismounting, or when moving along the top of the track, if you hold the door
handle and the door is not properly closed, the door may move and cause you to fall. Always make
sure that the door is properly closed.
Use the parts marked by arrow A in the diagram below when getting on or off the machine.
Use the parts marked by arrow B for mounting and dismounting only when the work equipment
is not installed.
Never use the parts marked by arrow C when getting on or off the machine. Use them only when
moving along the top of the track or when checking or carrying out maintenance inside the side
cover.
AM085840 AM085850
l-4
A WARNING: Failure to follow these safety precautions may lead
to a serious accident. 6. GENERAL PRECAUTIONS
FIRE PREVENTION FOR FUEL AND OIL 1

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be
HAZARDOUS.
l Keep a flame away from flammable fluids.
l Stop the engine and do not smoke when refueling.
l Tighten all fuel and oil caps securely.
l Refueling and oiling should be made in well ventilated areas.
l Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
A0055020 AM)55030 A0055040
BURN HAZARD
l If the coolant, engine oil, power train oil or hydraulic oil is hot, use a heavy cloth, gloves, heavy
clothing and safety glasses or goggles before checking or touching.
l To prevent hot water from spurting out:

1) Turn engine off.
2) Allow water to cool.
3) Slowly loosen cap to relieve pressure before removing.
l To prevent hot oil from spurting out:

I) Turn engine off.
2) Allow oil to cool.
3) Slowly loosen cap to relieve pressure before removing.
l-5
A ;;:?$;Wde Foiereasons qf safety, always
6. GENERAL PRECAUTIONS ty precautions.
l Asbestos dust can be HAZARDOUS to your health if it is inhaled.
l If you handle materials containing asbestos fibers, follow these guidelines as given below:
1) NEVER use compressed air for cleaning.
2) Use water for cleaning to minimize dust cloud.
3) Operate the machine with the wind to your back, whenever possible.
4) Use an approved respirator if necessary.
I Aoo55mo
I I
1 CRUSHING OR CUTTING PREVENTION 1
I
l Do not enter, or put your hand or arm or any other part of your body between movable parts such
as between the work equipment and cylinders, or between the machine and the blade or ripper
or any other attachment.
If the work equipment is operated, the clearance will change and this may lead to serious damage
or personal injury.
A0055230 I
FIRE EXTINGUISHER AND FIRST AID KIT

1
Be sure fire extinguishers have been provided and know how to use them.
Know where a first aid kit is located.
Know what to do in the event of a fire.
Be sure you know the phone numbers of persons you should contact in case of an emergency.
Equipping the fire extinguisher and the first-aid kit

-) See “30. EQUIPPING THE FIRE EXTINGUISHER AND FIRST-AID KIT”.
l-6
to a serious accident. 6. GENERAL PRECAUTIONS
Do not operate machine with ROPS removed if equipped.
The ROPS is installed to protect the operator if the machine should overturn. It is designed not
only to take the load when the machine overturns, but also to absorb the impact energy.
The Komatsu ROPS fulfills all worldwide regulations and standards, but if any unauthorized
modification is carried out on it, or if,it is damaged when the machine overturns, its strength will
be reduced and it will not-,be able to provide its original capacity. It will be able to provide this
capacity only if modifications and repairs are carried out in the specified way.
‘,
When carrying out modification or repairs, always consult your Komatsu distributor first.
Even when the ROPS is installed, if you do not fasten your seat belt securely, it cannot protect
your properly. Always fasten your seat belt when operating the machine.
Seat belts - See “27. USING SEAT BELT.”
PRECAUTIONS FOR AlTACHMENTS 1

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.
Any injuries, accidents, product failures resulting from the use of unauthorized attachments will
not be the responsibility of Komatsu.
J
1-7
A E;poR,N;M& Fooeeasons of safety, always
6. GENERAL PRECAUTIONS y precauttons.
--/ MACHINES WITH ACCUMULATOR 1

1 I
On machines equipped with an accumulator, for a short time after the engine is stopped, if the
work equipment control lever is moved to the LOWER position, the work equipment will move down
under its own weight.
After stopping the engine, always place the safety lock lever in the LOCK position.
When releasing the pressure inside the work equipment circuit on machines equipped with an
accumulator, follow the procedure given in the inspection and maintenance section.
Method of releasing pressure + See “29 HANDLING ACCUMULATOR.”
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.
l Never make any hole in the accumulator or expose it to flame or fire.
l Do not weld any boss to the accumulator.
l 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 4 See “29 HANDLING ACCUMULATOR.”
I
1-8
7. PRECAUTIONS DURING A WARNING: Failure to follow these safety
OPERATION precautions may lead to a serious accident.
7.1 BEFORE STARTING ENGINE

SAFETY AT WORKSITE
Before starting the engine, thoroughly check the area for any
unusual conditions that could be dangerous.
Before starting the engine, examine the terrain and soil condi-
tions of the worksite. Determine the best and safest method of
operation.
If you need to operate on a street, protect pedestrians and cars

by designating a person for worksite traffic duty or by installing
fences around the worksite.
If water lines, gas lines, and high-voltage electrical lines may be

buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or cut any of these lines.
Check the depth and flow of water before operating in water or

crossing a river. NEVER be in water which is in excess of the
permissible water depth.
Permissible water depth + See “12.9.1 PERMISSIBLE WATER
DEPTH”. AM085860
FIRE PREVENTION ]
Thoroughly remove wood chips, leaves, paper and other flammable things accumulated on the
engine compartment. They could cause a fire.
Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks repaired. Wipe up any
excess oil, fuel or other flammable fluids.
Check point -+ See “12.1.1 WALK-AROUND CHECK”.
Be sure a fire extinguisher is present and working.
AM)55020
1-9
A g&Ftt;;zeE;ereasons of safety, always
7. PRECAUTIONS DURING OPERATION ty precautrons.
Do not leave tools or machine parts around the operator’s compartment. They may damage the
control levers or switches and may even cause accidents. Always use the tool box inside the
engine compartment (left side).
Tool box + See “11.13 TOOL BOX”.
Keep the cab floor, controls, @stepsand handholds free of oil, grease, snow, and excess dirt.
Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts.
Always use seat belts when operating your machine.
Seat belts + See “27. USING SEAT BELT”.
I I
1 VENTILATION FOR ENCLOSED AREAS 1
l If it is necessary to start the engine within an enclosed area, provide adequate ventilation. Exhaust
fumes from the engine can KILL.
L A0055060
1 PRECAUTIONS FOR MIRRORS, WINDOWS AND UGHTS 1

l Remove all dirt from the surface of the windows and lights to ensure that you can see well.
l Adjust the rear view mirror so that you can see clearly from the operator’s seat, and always keep
the surface of the mirror clean. If any glass is broken, replace it with a new part.
l Check that the head lamps and rear lamps are installed to match the operating conditions. Check
also that they light up properly.
J
4 PRECAUTIONS FOR SLIDING GLASS INTERMEDIATE LOCK 1

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.
Do not put your head or hands out of the window during operations.
I-10
A ~;;M~C;~;;~o follow these safety precautions may lead
7. PRECAUTIONS DURING OPERATION
7.2 OPERATING MACHINE

WHEN STARTING ENGINE 1
Walk around your machine again just before mounting it, checking for people and objects that
might be in the way.
NEVER start the engine if a warning tag has been attached to the control.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
Do not allow anyone other than the operator to ride in the cab or on the machine body.
Check that the backup alarm is working properly.
Do not add grease or oil after starting the engine.
-/ PRECAUTIONS WHEN MOVING FORWARD OR BACKWARD 11

Before moving machine or its attachments:
Honk horn to alert people nearby.
Be sure no one is around machine, particularly behind machine.
Use spotter if necessary, particularly if you are moving in reverse.
When operating in areas that may be hazardous or have poor visibility, designate a person to direct
worksite traffic.
Prevent people from entering the line of travel of the machine.
Follow above even if equipped with back-up alarm and mirrors.
t
A0055080
1-11
A ~$;;;~e~;e-easons of safety, always
7. PRECAUTIONSDURING OPERATION y precautrons.
1 TRAVELING ON SLOPES 1
Traveling on hills, banks or slopes that are steep could result in the machine tipping over or
slipping.
On hills, banks or slopes, carry the work equipment closer to the ground, approximately 20 to 30
cm (8 to 12 in) above the ground. In case of emergency, quickly lower the work equipment to the
ground to help the machine stop and prevent it from tipping over.
Do not change direction on slopes. Avoid sideways travel whenever possible: rather travel up and
down the slopes.
Do not travel up and down on grass, fallen leaves, and wet steel plates. These materials may allow
the machine to slip, if it is traveling sideways. Keep travel speed very low.
When traveling downhill, drive slowly and use the engine as a brake
When traveling downhill with the machine being pushed by its own weight, the machine may steer
in the opposite direction, so be careful when steering.
Reverse steering when traveling downhill + See “12.7.2 TURNING WHILE DESCENDING A
SLOPE”.
INCORRECT CORRECT
AW51690
VISIBILITY
l Turn ON the head lamps and rear lamp, when working at night or at dark sites. Provide additional
lights for the worksite if necessary.
l If visibility is diminished by fog, snow or rain, stop operation. Wait until there is adequate visibility
for safe operation.
l Snow-covered and frozen ground may allow the machine to slip sideways, even if the grade is
not steep. Slow down the machine when traveling on such ground. Avoid rapid starts, stops, and
steering.
l In snow removal work, pay special attention to the edge of the road and to objects under the snow.
1-12
to a serious accident. 7. PRECAUTIONS DURING OPERATION
WORKING ON LOOSE GROUND 1

Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these
areas collapse, your machine could fall or tip over and result in serious injury or death. Remember
that the soil after heavy rain or blasting is weakened in these areas.
Earth laid on the ground and the soil near ditches are loose. They can collapse under the weight
or vibration of your machine.
Install the HEAD GUARD or FOPS if working in areas where there is danger of falling rocks and
dirt.
When working in places where there is danger of falling rocks or danger of the machine turning
over, install ROPS and a seat belt.
Park on level ground whenever possible. If not possible, block the tracks, lower the blade to the
ground and thrust the edge of the blade in the ground.
When parking on public roads, provide fences and signs, such as flags or lights, on the machine
to warn passersby to be careful. Be sure that the machine, flags or lights do not obstruct traffic.
Parking procedure -) See “12.10 PARKING MACHINE”.
Before leaving the machine, lower the work equipment to the ground, move the SAFETY LEVER
to LOCK position, stop the engine, and lock all the doors, windows, and covers and remove the
key(s).
Work equipment posture -+ See “12.10 PARKING MACHINE”.
Locks -+ See “12.14 LOCKING”.
1-13
a 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.
ALWAYS block the wheels of the hauling vehicle and place blocks under both ramps before
loading and unloading.
ALWAYS use ramps of adequate strength. Be sure the ramps are wide and long enough to provide
a safe loading slope.
Be sure that the ramps are securely positioned and fastened, and that the two sides are at the same
level as one another.
Be sure the ramp surface is clean and free of grease, oil, ice and loose materials. Remove dirt from
the machine tracks.
NEVER correct your steering on the ramps. If necessary, drive away from the ramps and climb
again.
After loading, block the machine tracks and secure the machine with tie-downs.
Loading and unloading - See “13. TANSPORTATION”.

Tie-downs + See “13. TRANSPORTATION”.
CORRECT I
Distance between ramps

AD052900
_ . .._ . _ __
l When shipping the machine on a hauling vehicle, obey all state and local laws governing the
weight, width, and length of a load. Also obey all applicable traffic regulations.
l Determine the shipping route while taking into account the width, height and weight of the load.
1-14
to a serious accident. 7. PRECAUTIONS DURING OPERATION
7.4 BATTERY
Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing.
If you spill acid on yourself, immediately flush the area with water.
Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them
immediately with large quantities of water and see a doctor at once.
If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil.
Call a doctor or poison prevention center immediately.
When working with batteries. ALWAYS wear safety glasses or goggles.
Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a
small spark or flame.
Before working with batteries, stop the engine and turn the starting switch to the OFF position.
Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such
as tools, across the terminals.
Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an
explosion.
Tighten the battery cap.
A0055090 A0055100 A0055110
1 STARTING WITH BOOSTER CABLES 1

ALWAYS wear safety glasses or goggles when starting the machine with booster cables.
When starting from another machine, do not allow the two machines to touch.
Be sure to connect the positive (+) cable first when installing the booster cables. Disconnect the
ground or negative (-1 cable first when removing them.
Connect the batteries in’parallel: positive to positive and negative to negative.
When connecting the ground cable to the frame of the machine to be started, be sure to connect
it as far as possible from the battery.
Starting with booster cables - See “16.2 IF BAlTERY IS DISCHARGED”.
INCORRECT
AM)52960 A0055110
A :/3/MEe Foiereasons of safety, always
7. PRECAUTIONS DURING OPERATION ty precautions.
7.5 TOWING
WHEN TOWING THE MACHINE, FIX THE WIRE
TO THE REAR HITCH PIN OR RIPPER
Injury or death could result if a disabled machine is towed incorrectly.
If your machine is towed by another machine, ALWAYS use a wire rope with a sufficient towing
capacity.
When the machine is towed, always set the steering and directional lever to the N (neutral)
position.
NEVER allow a disabled machine to be towed on a slope.
Do not use a kinked or frayed wire rope.
Do not straddle the towing cable or wire rope.
When connecting up a towing machine, do not let anyone enter the area between the towing
machine and the equipment being towed.
Set the towing machine and the towing connection of the equipment being towed in a straight
line when connecting it.
Take up the slack in the wire rope and tow the machine.
00 not tow over the maximum towing load.
When towing, confirm the maximum towing load indicated on

the rear drawbar, as shown in the illustration.
1-16
8. PRECAUTIONS FOR A WARNING: Failure to follow these safety
MAINTENANCE precautions may lead to a serious accident.
8.1 BEFORE CARRYING OUT MAINTENANCE

WARNING TAG
l If others start the engine or operate the controls while you are performing service or lubrication,
you could suffer serious injury or death.
l ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert others that
you are working on the machine. Attach additional warning tags around the machine, if necessary.
l These tags are available from your Komatsu distributor. (Part No. 09963-03000)
0.0 NOT operate

When this plate is not being used
keep it in the storage compartment.
\ 0996343000 J
1 l Use only tools suited to the task. Using damaged, low quality,
cause personal injury.
faulty, or makeshift tools could 1
Tools - See “21.1 INTRODUCTION OF NECESSARY TOOLS”.
l Replace the following fire-related components periodically:

Fuel system: Fuel hose, spilling hose, and fuel tube cap
Hydraulic system: Pump outlet hoses
l Replace these components periodically with new ones, regardless of whether or not they appear
to be defective; These components deteriorate over time.
l Replace or repair any such components if any defect is found, even though they have not reached
the time specified.
Replacement of safety critical components - See “22. PERIODIC REPLACEMENT OF SAFETY

CRlTlCAL PARTS”.
1-17
A ~;~Wl~e~;ereasons of safety, always
8. PRECAUTIONSFOR MAINTENANCE ty precautrons.
STOP THE ENGINE BEFORE CARRYING

OUT INSPECTION AND MAINTENANCE
Always stop the machine on firm flat ground and stop the engine before carrying out inspection
and maintenance.
If it is necessary to run the engine when carrying out maintenance, such as when cleaning the
inside of the radiator, place the safety lock lever at the LOCK position and carry out the operation
with two workers.
One worker should sit in the operator’s seat so that he can stop the engine immediately if
necessary. He should also be extremely careful not to touch any lever by mistake. Touch the levers
only when they have to be operated.
The worker carrying out the maintenance should be extremely careful not to touch or get caught
in the moving parts.
If maintenance is carried out with the work equipment raised, always support it securely with
blocks.
OFF
ADO51781
1-18
A ~JJP$JW& fygzn:p follow these safety Precautions may lead
8. PRECAUTIONSFOR MAINTENANCE
8.2 DURING MAINTENANCE
l Only authorized personnel can service and repair the machine.

Extra precaution should be used when grinding, welding, and
using a sledge-hammer.
4 ATTACHMENTS 1
l Place attachments that have been removed from the machine in
a safe place so that they do not fall. If they fall on you or others,
serious, injury could result.
WORK UNDER THE MACHINE

l Always lower all movable work equipment to the ground or to
their lowest position before performing service or repairs under
the machine.
l Always block the tracks of the machine securely.
l Never work under the machine if the machine is poorly sup-

ported.
KEEP .THE MACHINE CLEAN

l Spilled oil or grease, or scattered tools or broken pieces are
dangerous because they may cause you to slip or trip.
Always keep your machine clean and tidy.
l If water gets into the electrical system, there is danger that the
machine may not move or may move unexpectedly.
Do not use water or steam to clean the sensors, connectors, or
the inside of the operator’s compartment.
1-19
A j%+~;$\;G;e Fooeeasons of safety, always
8. PRECAUTIONSFOR MAINTEN,ANCE y precauttons.
RULES TO FOLLOW WH-,

l Spilled fuel and oil may cause you to slip, so always wipe it up immediately.
l Always tighten the cap of the fuel and oil fillers securely.
l Never use fuel for washing any parts.
l Always add fuel and oil in a well-ventilated place.
A0055020 ADO55030
RADIATOR WATER LEVEL

l If it is necessary to add water to the radiator, stop the engine and allow the engine and radiator
to cooi down before adding the water.
l If removing the radiator cap, turn it slowly to release the internal pressure.
I I
_I USE OF LIGHTING 1
l When checking fuel, oil, coolant, or battery electrolyte, always use lighting with antiexplogion
specifications.
If such lighting equipment is not used, there is danger of explosion.
l-20
to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS WITH BAlTERY

l When repairing the electrical system or when carrying out electrical welding, remove the negative
(4 terminal of the battery to stop the flow of current.
l Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked
piping, tubes or hoses. They may burst during use.
l Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.
l Avoid torching, soldering, or welding on pipes, tubes and equipment that contain fuel or oils.
If heated, they can generate flammable fumes or mist and could cause a fire or explosion.
l Do not forget that the work equipment circuits are always under pressure.
l Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the
internal pressure.
l If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure
oil hits your skin or enters your eyes. Always wear safety glasses and thick gloves, and use a piece
of cardboard or a sheet of wood to check for oil leakage.
l If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
A0055190 A0055190
1-21
A z;:.;;Ee Fooeeasons of safety, always
8. PRECAUTIONSFOR MAINTENANCE y precautrons.
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT

HIGH TEMPERATURE OR HIGH PRESSURE
l Immediately after stopping operations, the engine cooling water and oil at all parts is at high
temperature and under high pressure.
In this condition, if the cap is removed, or the oil or water are drained, or the filters are replaced,
this may result in burns or other injury. Wait for the temperature to go down, then carry out the
inspection and maintenance in accordance with the procedures given in this manual.
Clean inside or cooling system -) See “24.1 WHEN REQUIRED”.
Check cooling water level, lubricating oil level + See “24.2 CHECK BEFORE STARTING”.
Checking oil level in hydraulic tank, final drive case + See “24.4 PERIODIC MAINTENANCE”.
Changing oil, replacing filters + See “24.5 - 7 PERIODIC MAINTENANCE”.
PRECAUTIONS WHEN USING HIGH PRESSURE

GREASE TO ADJUST TRACK TENSION
Grease is pumped into the track tension adjustment system under high pressure.
If the specified procedure for maintenance is not followed when making adjustments, the plug or
grease fitting may fly out and cause damage or personal injury.
l When loosening the grease drain plug, never loosen it more than one turn.
I l Never put your face, hands, feet, or any other part of your body directly in front of any grease
drain plug or valve.
Adjusting track tension 4 See “24.1 WHEN REQUIRED”.
ROTATING FAN AND BELT

l Keep away from rotating parts and be careful not to let.anything get caught in them.
l If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying, so never
touch any rotating parts.
A0055210
l-22
A kV$RsIUU~G;F,acib.rdr~$o
follow these safety precautions may lead
8. PRECAUTIONSFOR MAINTENANCE
4 WASTE MATERIALS 1
l Never dump waste oil in a sewer system, rivers, etc.
l Always put oil drained from your machine in containers. Never drain oil directly on the ground.
l Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, batteries, and others.
INCORRECT
A0055220
l-23
9. POSITION FOR ATTACHING SAFETY LABELS
Always keep these labels clean. If they are lost or damage,

attaching them again or replace them with a new label.
There are other labels in addition to the safety labels listed as
follows, so handle them in the same way.
Safety labels may be available in languages other than English.
To find out what labels are available, contact your Komatsu
distributor.
9.1 POSITION FOR ATTACHING SAFETY LABELS
AN140240
l-24
9. POSITION FORA-I-I-ACHINGSAFETYLABELS
1. Warnings before operating machine 3. Warnings for leaving operator’s seat

(14X-98-l 1580) (14X-98-11541)
g, WARNING - A WARNING :
improper operation and main- To avoid hitting unlocked
tenance can cause serious operation levers, before stand-
ing up from operator’s seat, do
injury or death.
the following:
Move steering and direc-
Read manual and labels before tional lever neutral and
operation and maintenance. move SAFETY LOCK LEVER
Follow instructions and warn- (located left of seat) to LOCK
ings in manual and in labels on position.
Lower equipment to ground
machine.
and move SAFETY LOCK
LEVER (located right of seat)
Keep manual in machine cab to LOCK position.
near operator.
Contact Komatsu distributor Sudden and unwanted machine
for a replacement manual. movement can cause serious
injury or death.
. 14X-98-11580 J c 14X-98-11541 1
2. Warnings before moving in reverse 4. Warnings for hot water hazard

(14X-98-11590) (14X-98-11531)
A WARNING A WARNING
Hot water hazard.
To prevent hot water from

spurting out:
l Turn engine off.
l Allow water to cool.
0 Slowly loosen cap to relieve
pressure before removing.
Before moving machine or its
attachments:
l Honk horn to alert people
nearby.
l Be sure no one is on machine
area.
0 Use spotter if necessary,
particularly if you are moving
in reverse.
Follow above even if equipped
with back-up alarm and mirrors.
t 14X-98-11590 -
l-25
9. POSITION FOR ATTACHING SAFETY LABELS
5. Warnings for hot oil hazard 8. Warning to prevent entry during maintenance
(14X-98-11521) Display this sign around the bulldozer.
(17A-98-11530)
A WARNING
Hot oil hazard.
To prevent hot oil from spurt-

ing out:
Turn engine off.
Allow oil to cool.
Slowly loosen cap to relieve
pressure before removing. Keep a safe distance
17A-98-11530
. 14X-98-11521 -
6. Warnings for adjusting track tension

(14X-98-11551) 9. Warning for ROPS (09620-30202)
.
/ ROLL.O”ER PROTECTIVE STRUCTURE ,ROPSI CERTIFICATION
A WARNING - THlS KOMATSU ROFS, MOML .9 type No. ISERIAL ND. OWEN
WSTALLED IN ACCORDANCE WITH THE MANUFACTURES INSTALLATION IN.
STRUCTIONS ON A I ‘0; ‘;1E;L$‘9$;44;$
KOMAlbU MASS NOT GREATER THAN 1 I
COMPLY ‘WC-4 THE FOLLOWING REOUIREMENTS: a, 0S”A 29CFR. 1926.1991
High pressure hazard at track
b) IS0 3611 ,ROPS, c) SAE J nle SAE J r-1
adjuster.
I * Alterinq ROPS may weaken it. Consult Komatsu Distributor before
When adjusting track tension, altering.
* RDPS may provide less protection if it has been Structur9lly dam-
never open plug more than one aged or involved in roll-over.
turn. * Always wear SSat belt when moving.
Turning further could cause injury Komatsu Ltd. Japan 2-3-6 Akasaka. Minato-ku, Tokyo. Japan 09620-30202
from flying plug and grease.
See manual for adjustment in-

structions.
\ 14X-98-11551 -
7. Warning for handling accumulator

(14X-98-l 1390)
l-26
OPERATION
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.
Machines equipped with cab

Cab
Engine
I A/
Lift cylinder I/< \
Radiator mask
.Track shoe
’ idler AN140290
Machines equipped with canopy Cayrv
Rear
AM095930
2-2
10. GENERALVIEW
10.2 GENERAL VIEW OF CONTROLS AND GAUGES
Head lamp switch Rear lamp switch
Air conditioner panel or heater panel
Fuel control lever Bmke pedal

Joystick Deceferation pedal
1Sieeriq directional and
gear shl lever) / _. . -A_-.I
maf8e comrol lever
‘1
Speed range display
Horn switch
Cigarette lighter \
\ ! \
Transmission oil
i
Parkin; lever
Monitor caution
AM085950
Monitor caution lamp

Wiper
._._.. ---._~switch
Engine water
temperature
caution lamp
2-3
-
Machines equipped with canopy
Monitor panel specification
Rear lamp switch

Head lamp switch Glow switch
Fuel control lever

Joystick
(Steering, directional
and gear shift lever)
de control lever
Horn switch
AM066010
Engine water Transmission oil

temperature auge temperature gauge
[ i /Fuel gauge
Service meter
/
Parking lever
zf:I z+jz> Monitor caution lamp
Engine Later Engine oil pressure

temperature caution lamp
caution lamp
AM065960
__- ---_
2-4
Gauge panel specification
Rear lamp switch
Joystick
(Steering, directional
and gear shift lever)
de control lever
Speed range display window
rn switch
AM088840
Engnie water Transmission oil

temperature gauge temperature gauge
Parking lever
AM085950
signal
caution lamp
AW5535A
2-5
11. EXPLANATION OF COMPONENTS
The following is an explanation of the devices needed for

operating.@ 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.
l- D65E-12, D65P-12
1
Equipment Section No.
Canopy Cab
I
Front panel
Monitor panel 11.1.1
-IT--- --
1
Gauge panel 11.1.2
r-
Air conditioner panel 11.1.3
Heater panel 11.1.4

---__- -
Switch panel (cab) 11.1.5 -
Switch panel (canopy) 11.1.6

i ___.._.______________________.__._____.___
Switches
_-_-. ____.. _~__.___-__.-_..__-_-_-_---.
t 11.2 1
Horn switch t
1
Room lamp switch 11.2 2
Cigarette lighter 11.2 3
Wiper switch 11.2 4

Additional working lamp switch 11.2 5 -
- ~___
c
- ntrol levers, pedals
__-L.- _~______ --
Fuel control lever 11.3 1
Joystick (steering, directional and gear shift lever) 11.3 2
Brake pedal 11.3 3
Decelerator pedal 11.3 4
Parking lever 11.3 5
Safety lever (for blade control lever) 11.3 6
Blade control lever 11.3 7
Power tiltdozer specification

,’
Power tilt, power pitch dozer specification
Angle dozer specification ,
2-6
11.1 FRONT PANEL (METERS, LAMPS,

SWITCHES)
11.l. 1 MONITOR PANEL
(MONITOR PANEL SPECIFICATION)
1. SERVICE METER
This meter shows the total operation hours of the machine. The
service meter advances while the engine is running - even if the
machine is not traveling.
Set the periodic maintenance intervals using this display.
When the engine is running, the green pilot lamp @ at the top
of the meters flashes to indicate that the meter is advancing.
Meter 2 will advance by 1 for each hour of operation regardless
of the engine speed.
I 1
White
2. ENGINE WATER TEMPERATURE GAUGE
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
ADO51614
down to the white range.
After starting the engine, warm up it until the indicator moves
into the white range.
2-7
11. EXPLANATIONOF COMPONENTS
3. TRANSMISSION OIL TEMPERATURE GAUGE

White Red
This 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
ADO51615
white range.
4. FUEL GAUGE
When the starting switch is turned ON, this 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 e (11.35 US gal, 9.46 UK gal) remaining, so add fuel.
Always fill the tank after finishing operations.
AW5.1616
5. ENGINE WATER TEMPERATURE CAUTION LAMP 1

This 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 to go down to the white range.
I ADO51617
-I
6. CHARGE LAMP
This lamp indicates malfunction of the alternator.
10
When the starting switch is turned ON, it will light up, but it
7l
should go out when the engine speed rises.
If the lamp lights up during operation, stop the engine and check
the V-belt tension. If any abnormality is found, see “16. TROUBLE-
- +II
ri I)
SHOOTING”.
AM)51616
7. ENGINE OIL PRESSURE CAUTION LAMP

This lamp warns that the engine lubricating ‘oil pressure has
dropped. When the starting switch is turned ON, it will light up.
When the lamp goes off after the engine is started, the oil
pressure is normal.
When the lamp lights up during operation, the oil pressure is
lower.
Immediately stop the engine and look for the cause. For details, AD051619
see “16. TROUBLESHOOTING”.
8. GLOW SIGNAL LAMP

This indicates the electrical intake air heater is red-heated. 0
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.
Ll 0
aF
ADS5161A
2-8
9. TRANSMISSION OIL TEMPERATURE CAUTION LAMP

This warns the operator that the oil temperature at the transmis-
sion 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 tempera-
ture gauge to go down to the white range.
AM086030
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.
ADO5161C
11. MONITOR CAUTION CANCEL SWITCH

This switch is used to cancel monitor caution lamp @I. Press the
switch to turn the monitor caution lamp out and to stop the alarm
buzzer. iMl
&wEL
0
0
AD051610
2-9
11.1.2 GAUGE PANEL

(GAUGE PANEL SPECIFICATION)
AMOBEO40
1. SERVICE METER
This meter shows the total operation hours of the machine. The
service meter advances while the engine is running - even if the
machine is not traveling.
Set the periodic maintenance intervals using this display.
Meter will advance by 1 for each hour of operation regardless of the
engine speed.
AM088050
2. ENGINE WATER TEMPERATURE GAUGE

This gauge indicates the cooling water temperature.
When the indicator is in the green range during operation, the
water temperature is normal.
If the indicator moves from the green range into the red range
during operation, stop the machine immediately, run the engine
under no load at a midrange speed, and wait for the indicator to go
down to the green range.
AM086069
After starting the engine, warm up it until the indicator moves
into the green range.
2-10
3. TRANSMISSION OIL TEMPERATURE GAUGE

This indicates the temperature of the transmission lubricating
oil.
When the indicator is in the green range during operation, the
oil temperature is normal.
If the indicator moves from the green range into the red range
during operation, stop the machine, run the engine under no load
at a midrange speed, and wait for the indicator to go down to the
green range.
4. CHARGE LAMP
This lamp indicates malfunction of the alternator.
I I
When the starting switch is turned ON, it will light up, but it should
go out when the engine speed rises. +
If the lamp lights up during operation, stop the engine and check
/
the V-belt tension. If any abnormality is found, see “16.
TROUBLESHOOTING”.
5. ENGINE OIL PRESSURE CAUTION LAMP

This lamp warns that the engine lubricating oil pressure has
dropped. When the starting switch is turned ON, it will light up.
I I I
When the lamp goes off after the engine is started, the oil pressure
is normal.
When the lamp lights up during operation, the oil pressure is lower.
Immediately stop the engine and look for the cause. For details, see I 8
“16. TROUBLESHOOTING”. I AM066090
6. GLOW SIGNAL
This indicates the electrical intake air heater is red-heated.
When holding the starting switch key at the HEAT position, this
signal glows red after 15 - 45 seconds.
When releasing the key, the key will return to the OFF position and
the signal will go off.
AM666100
2-11
11.1.3 AIR CONDITIONER PANEL

(MACHINES EQUIPPED WITH CAB, AIR
CONDITIONER)
r------
ADO51621
-------~ ~_-
For details of handling switches !& to $$ below, see “11.15
HANDLING AIR CONDITIONER”.
1. FRESH/RECIRC SELECTOR LEVER 43 Q

This changes the air intake port used when cooling or heating. ( )
l RECIRC ( a ) uses the air inside the cab.
Turn the switch normally to this position when strong cooling is
needed. In this position, no ventilation or pressurizing is carried out. ADO51622
l FRESH ( iq ) takes in outside air.
This is the standard position for cooling and heating.
In this position, fresh air is brought in from outside to carry out
ventilation. In addition, the inside of the cab is pressurized to prevent
the entry of dust.
2. AIR CONDITION SWITCH

When the switch is pressed and the blue lamp lights up, the
cooling function is actuated. Use this switch for cooling or dehumidi-
fying.
ADO51623
2-12
3. BLOWER SWITCH
This 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.
1 ’ AD051624
J
TEMPERATURE CONTROL LEVER

This 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, the
temperature of the air coming from the vents becomes higher.
(The water valve is opened and the heating function is started.)
ADO51625
STARTING SWITCH
This switch is used to start the engine.
OFF ( C@) position:

At this position, the starting switch key can be inserted or
removed. When the switch is turned to this position, the electrical
circuits are switched off.
Do not the starting switch key at the OFF position while the
engine is running.
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 ( 13 ) 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.
2-13
11.1.4 HEATER PANEL

(MACHINES EQUIPPED WITH CAB, HEATER)
ADO51631
._.._ _-._. _._.-.--~.----_- __.-_ ..- _.-. ---
r------l
For details of handling switches \I to (5, below, see “11.16
HANDLING HEATER”.
FRESH/RECIRC SELECTOR LEVER

This changes the air intake port used when cooling or heating.
RECIRC ( :I ) uses the air inside the cab.
T;rn the switch normally to this position when strong cooling is
needed. In this position, no ventilation or pressurizing is carried
out.
FRESH ( ,:I ) takes in outside air.
This is the standard position for cooling and heating.
In this position, fresh air is brought in from outside to carry out
ventilation. In addition, the inside of the cab is pressurized to
prevent the entry of dust.
BLOWER SWITCH
This acts as the wind flow control switch and main switch when
cvoling or heating.
7he air flow can be set to three stages: 1 (LOW) + 2 (MEDIUM)
‘-9 3 (HIGH).
If the switch is set to 0, the power is switched off and the heater
stops.
ADO51632
-_--
2-14
TEMPERATURE CONTROL LEVER

This is used to control the temperature
When the temperature control
for heating.
lever is moved to the right, the
1
temperature of the air coming from the vents becomes lower.
When the temperature control lever is moved to the left, the
temperature of the air coming from the vents becomes higher.
1 AD051633
-I
STARTING SWITCH
OFF
OFF ( ir21 ) position:

engine is running.
ON position:
In this position, electric current flows in the charging and lamp
circuits.
is running.
START ( I’-?, ) position:

This is’the position to start the engine. Hold the key at this
position while cranking. Release the key immediately after the
released.
2-15
11.1.5 SWITCH PANEL

(MACHINES EQUIPPED WITH CAB)
I Aoo51730
1. HEAD LAMP SWITCH

This lights up the head lamps.
OFF ON
OFF position: Lamps are out
IJ
ON position: Lamps light up
ADOS1790
2. REAR LAMP SWITCH

This lights up the rear lamps.
ADO51790
2-16
l
3. GLOW SWITCH
This 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 temperature is below approx. -5°C.
I position: This is used when AUTO preheating is not enough to start
the engine in cold weather simply 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.
2-17
11.1.6 SWITCH PANEL

(MACHINES EQUIPPED WITH CANOPY)
1. HEAD LAMP SWITCH

This lights up the head lamps.
OFF ON
l.J
ADO51790
2. REAR LAMP SWITCH

This lights up the rear lamps.
AC051790
2-18
3. GLOW SWITCH (MONITOR PANEL SPECIFICATION1

This 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
ADO51791
the ambient temperature is below approx. -5°C.
I position: This is used when AUTO preheating is not enough to start

the engine in cold weather simply with the glow switch 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.
4. STARTING SWITCH
OFF ( ,;.) ) position:

OFF
engine is running.
-START
ON position:
AD051780
In this position, electric current flows in the charging and lamp
circuits. Gauge panel specification
is running.
p\ ) position:
START ( k_r
This is the position to start the engine. Hold the ,key at this
position while cranking. Release the key immediately after the - START
AM086140
released.
HEAT ( 3 1 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 immediately
to the START position to start the engine.
2-19
11.2 SWITCHES
1
AM066150
--
__--__ -__._-_..
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.
ON position: Lamp lights up
OFF position: Lamp is out
AD051820
3. CIGARETTE LIGHTER (MACHINES EQUIPPED WITH CAB)

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.
NOTICE
This cigarette lighter is 24V. Do not use it as the power source AW51630
for 12 V equipment.
2-20
4. WIPER SWITCH (MACHINES EQUIPPED WITH CAB)

This activates the wipers.
The wiper switches are as foliOWS.
@ Left door
@ Front window
c& Right door
(3 Rear window
This is also used as the window washer switch.

The switch is operated as follows.
l Window washer only

Keep the switch pressed to the OFF position to spray out water.
ADO51850
0 Wiper only
If this is switched on, the wiper will start.
ADO51860
I I
a Wiper and window washer I I

If this is kept pressed to the ON position while the wiper is
working, water will be sprayed out.
ADO51870
2-21
5. ADDITIONAL WORKING LAMP SWlTCH

This is used to turn on the additional working lamp.
@ Head lamp switch
@ Rear lamp switch
Push in the direction of the arrow to turn on the lamps.
AD051880
2-22
11.3 CONTROL LEVERS, PEDALS
FUEL CONTROL LEVER

This lever is used to control the engine speed and output.
Engine stop position: Push the lever forward fully.
Low idling position: Pull the lever from engine stop position @
until you feel the operating force falls off.
High idling position: Pull the lever fully from low idling position
I .- ADO56361
2-23
2. JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER)

This is used to select the direction of travel, to select the speed
range of transmission, to carry out steering, and to carry out
counterrotation turns.
Forward-reverse shifting
..I.‘: FORWARD
..q: REVERSE
N: NEUTRAL
Push the lever forward, the machine will move off forward.
Pull the lever backward, the machine will move off in reverse.
Steering
:I+: LEFT TURN
\.P: RIGHT TURN
Move the joystick to the FRONT to travel FORWARD

Move the joystick to the REAR to travel in REVERSE
If the joystick is operated to travel forward or in reverse, and is
then moved partially in the direction of turn, the machine will turn
gradually.
If the joystick is moved further in the direction of turn, the
machine will turn more sharply.
REMARK
if the lever is released when steering the machine, the lever will
return to the I ! position or the @ position and the machine will be ADO55470
returned to straight movement.
If you support the lever guide with your hand when steering, the
turning operation will be easier.
Gear shifting
Rotate the joystick 30” to carry out gear shifting operation.
Position .AJ : 1st
Position :a; : 2nd
Position ic, : 3rd AD055362
REMARK
When gear shifting operation is carried out, the display panel at
the rear of the joystick will display the speed range.
1st: iiis displayed on the display panel
2nd: 2.1is displayed on the display panel
3rd: 31 is displayed on the display panel
2-24
3. BRAKE PEDAL
a WARNING
Do not place your foot on this pedal unnecessarily.
Depress the pedal to apply the right and left brakes.
4. DECELERATION PEDAL
This pedal is used for reducing the engine speed or stopping the
machine.
Depress this pedal to reduce the speed when shifting between
forward and reverse or when stopping the machine.
5. PARKING LEVER
When the machine IS parked, always set the parking lever to the
/rocnpa.itio.* wARNlNG’I
This lever is used to apply the parking brake.
REMARK
l When the steering and directional lever is at the FORWARD or
REVERSE position, if the parking brake lever is operated to the
LOCK position, the steering and directional lever will automatically
return to the N position.
l The engine will not start if the parking brake lever is not at the
LOCK position.
2-25
6. SAFETY LEVER (FOR BLADE CONTROL LEVER)
11 g 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.
If the safety 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 safety lever
to the LOCK position.
This safety lever is a device to lock the blade control levers.

When it is set to the LOCK position, the TILT, LOWER, and FLOAT
operations are locked.
If the blade control lever is at the FLOAT .position and the safety
lever is set to the LOCK position, the blade control lever is automati-
cally returned to the HOLD position.
REMARK
If the blade control lever is at the FLOAT position, the engine will
not start. To start the engine, first set the safety lever to the LOCK
position.
2-26
7. BLADE CONTROL LEVER

(POWER TILTDOZER)
This lever is used to raise or tilt the blade.
Lifting control _.
r!_> RAISE : ( ’ )
12. HOLD : (_) %
Blade is stopped and held in this position,
~,$;~LOWER : ( ’ )
:\{j FLOAT : ( % )
Blade will move freely according to external force.
REMARK
l When released from FLOAT position, this lever will not return to
HOLD position, so it must be moved back by hand.
l If the engine is stopped when the lever is at the FLOAT position,
the control lever will automatically return to the HOLD position. AMOS527C
l Before starting the engine, check that the blade control lever is
at the HOLD position.
l 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
& LEFT TILT : (t_,,
$ij RIGHT TILT : (,,I,
2-27
7. BLADE CONTROL LEVER

(FOR POWER TILT, POWER PITCH DOZER)
This carries out the blade lift, tilt, and pitch operations.
Lifting control
.I,,, RAISE : ( ’ )
i.2, HOLD : (_I
k
Blade is stopped and held in this position.
.3 LOWER : ( ’ )
4 FLOAT : (_I%
REMARK Raise
l If the engine is stopped when the lever is at the FLOAT position, Lowe
the control lever will automatically return to the HOLD position.
l Before starting the engine, check that the blade control lever is I AMOS6270

i In cold weather, it will take time for the lever to be held at the
Tilting control
i& LEFT TILT : (I,,,
\B RIGHT TILT : L,r,
Pitch control
,,n REAR PITCH: Min. digging angle
!$I FORWARD PITCH: Max. digging angle
First set the lever to the neutral position, then keep switch @I in
the center of the knob pushed down and carry out the tilt operation
to change the cutting angle of the blade.
2-28
Precautions when using pitch control

When using the pitch operation, the tilt operation changes as
follows.
Pitch condition Tilt operation Amount of tilt
Only left tilt

Max. forward pitch 1 Max. 890 mm (35.1 inl
I operation is possible
/ AM086300
!
Forward pitch
-_-- Both left and right

---I
tilt operations are 445 mm ((17.5 in1
Standard pitch
possible both left and right)
Rear pitch
Only right tilt

Max. rear pitch Max. 890 mm (35.1 in)
operation is possible
7. BLADE CONTROL LEVER (FOR ANGLEDOZER)

This lever is used to raise the blade.
Lifting control
\!.a RAISE : (&,
t.2‘ HOLD : (A_ 1
Blade is stopped and held in this position.
,.? LOWER : ( ’ )
,4 FLOAT : (__I
%
REMARK
l If the engine is stopped when the lever is at the FLOAT position,
the control lever will automatically return to the HOLD position.
l Before starting the engine, check that the blade control lever is
l In cold weather, it will take time for the lever to be held at the
2-29
11.4 FUSE BOX
NOTICE
l Before replacing a fuse, be sure to turn off the starting switch.
o If the fuse blows again immediately after it is replaced, please
contact your Komatsu distributor to have the system inspected.
The fuses protect the electrical equipment and wiring from

AM086320
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.
l Chassis
When the battery cover is opened, two fuse boxes can be found
inside.
o Cab (machines equipped with cab)
It is installed at the bottom of the overhead panel.
11.4.1 FUSE CAPACITY AND CIRCUIT NAME

Fuse box ‘j
No. FUSE CAPACITY CIRCUIT NAME
1: 20 A Head tamp, Rear lamp

.--.-__ -
2 10 A Chassis power source AM086340
__-.-_-------
3. 10 A Engine control system
--.--~
4 10 A Horn
-.-
5. 10 A Back-up alarm
Fuse box ,2.
1,' 10 A Cab radio

-.- ---.. - -
? 10 A Power pitch selector
____ -___-
7 20 A Air conditioner
_.__.-___
4
--- --
5.; 10 A Chassis power source
Fuse box 13, (machine equipped with cab)
‘1 10 A Radio memory
- _...--.---
?. 20 A Radio, lamps, cigarette lighter
3; 10 A Rear wiper
-- -_.-...__
__ 4 t 10 A Right door wiper
__-____- w
AM086360
---I- 10 A Front wiper
~~--~~
.6. r 10 A 7 Left door wiper
2-30
11.5 GREASE PUMP HOLDER
This is inside, the left engine side cover.

Fit the grease pump to the holder when it is not being used.
,11.6 SHOVEL HOLDER
This can be used for storing a shovel with a rounded blade.
l Method of installing
1. Fix the shovel with stopper ;il;\and holder 0.
2. Tighten with adjustment nut 0 so that the shovel does not
move.
I AM086380
11 .7 DOOR-OPEN LOCK
Use this when your want to keep the door held open.
1. Push the door against the door catch. The door will be held by
the door catch.
2. To release the door, move lever (ij inside the cab to the front of
the cab. This will release the catch.
NOTICE
l When keeping the door open, fix lt securely to the catch.
l Always close the door when traveling or carrying out opera=
tions. Leaving the door open will cause the door to break.
l Keep the door locked open securely.
The door may swing closed because of the vibration.
2-31
11.8 SASH GLASS INTERMEDIATE LOCK

Do not stick your head or hand out of the window during
Even when the glass is locked, it may move because of shock

if the machine is started or stopped suddenly.
When carrying out operations with the cab sash glass open, use
this block to prevent the glass from moving.
l When the lever is at the FREE position, the glass can be opened
or closed.
l When the lever is moved to the LOCK (up or down) position, the
glass is fixed in position.
l If the glass is not held securely, set the lever in the FREE position
and rotate clockwise to strengthen the holding power.
l To reduce the holding power, turn counterclockwise.
NOTICE
Always close the window when traveling or carrying out opera-
tions. Leaving the window open will cause the window to break.
11.9 CAP WITH LOCK I
Lock is installed to the fuel tank filler cap.
Open and close locking cap as follows:

OCK
l To open the cap OPEN

1. Insert the starting switch key into the key hole on the cap.
AM086410
Insert the key as far as it will go. If the key is turned before it is
inserted all the way to the shoulder, it may break.
2. Turn the key clockwise, align the match mark on the cap with the
rotor groove, then remove the cap.
l To lock the cap.

1. Turn the cap into place.
2. Turn the key counterclockwise and take the key out.
AM066420
2-32
11.10 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.
11.11 DOOR POCKET

These are on the inside of the left and right doors, and can be
used for keeping things or Operation & Maintenance manual. How-
ever, do not put tools or other heavy objects in the pocket. If the
pocket becomes dirty, turn three clips <i:, remove the pocket and
wash it.
11.12 ASHTRAY
This is on the left side of the operator’s seat.

Always make sure that you extinguish the cigarette before
closing the lid.
11.13 TOOL BOX
This is used for keeping the tools.
AM066450
2-33
11.14 USING CAR RADIO

(MACHINES EQUIPPED WITH CAB, CAR RADIO)
11 s14.1 EXPLANATION OF PARTS
_r------ 0000000000
00000000000
000000000000
00000000000
000000000000
00000000000
0000000000
I. ruvvlEn 3VVI I b”, ““L”,V,E b”,” I rt”L RlYVD
(PUSH ON/VOL)
Push this knob to switch the radio on. The lighting in display area
\.i:j will light up and the frequency will be displayed. Press again to
switch the power off.
Turn the knob clockwise to increase the sound, and
counterclockwise to reduce it.
AW51642
2. TONE CONTROL KNOB (TONE)

Turn this knob clockwise from the center position to emphasize
the high sounds, and counterclockwise to emphasize the low sounds.
I AD051643
3. DISPLAY BUlTON (DISP)

If the display button is pressed when the ‘radio is being
used, the frequency of the station being listened to is displayed for
5 seconds.
2-34
Il. EXPLANATION OF COMPONENTS
4. TUNING/HOUR, MIN ADJUSTMENT BUlTON (TUNE)

This is used to select the station or change the frequency.
If the station UP button A is pressed, the frequency will go up by
9 kHz each time it is pressed; if the station DOWN button V is
pressed, the frequency will go down 9 kHz each time it is pressed.
If these buttons are kept pressed for more than 2 seconds, the
station will be selected automatically.
When adjusting the time, these change the hour display and minute
ADO51545
display.
I
5. PRESET BUTTON (1, 2, 3, 4, 5, 6)
These buttons can be used to program the desired broadcasting
stations. It is then possible to select the station at a touch.
6. TIME ADJUSTMENT BUTTON (T.ADJ)

Press this button to adjust the time.
0 T, ADJ
1 AD051547
7. TIME RESET BUTTON (RESET)

Press this button to reset to the exact hour.
0 RESET
ADO51548
8. DISPLAY
This displays the frequency, time, and preset symbols.
AD351649
2-35
11.14.2 METHOD OF USE

Method of setting preset buttons
1. Press power switch \I). The frequency is displayed in display
area 4;.
2. Use selector button 19 (A or V) to adjust to the desired frequency.
3. Choose a preset button to use for this station, and keep it
pressed for at least 2 seconds to program the button to that
frequency. AD05164A
When the sound suddenly disappears and appears again, the
button is programmed, and the preset number is shown in
display area &J.
After programming the button, press the preset button and
release it within approx. 2 sec. The station programmed to that
button will be selected for reception.
It is possible to program one station for each preset button.
Method of manual tuning

Press the tuning button lightly to adjust to the desired frequency.
Each time the button is pressed, the frequency will change by 9 kHz.
A button: Select station at higher frequency
V button: Select station at lower frequency
AD051645
Method of automatic tuning

Keep the tuning button pressed for at least 2 seconds and then
release it. When reception from a broadcasting station is picked up,
the selector will automatically stop at that position.
When searching for the next station, keep the selector button
pressed again for at least 2 seconds.
A button: Select station at higher frequency
v button: Select station at lower frequency ADO51645
If the reception is weak, and stations are not found, adjust the
frequency manually to select the desired station.
2-36
Adjusting time I
I. Keep T.ADJ button ;i‘\ pressed, and press H button 0.
The hour display will change, so when it reaches the correct
hour, release the button.
2. Keep T.ADJ button .i., pressed and press M button (3.
The minute display will change, so when it reaches the correct
time, release the button.
’ ADO51646
Method of using RESET button

If RESET button I : is pressed at the same time as the time signal
or standard time, the display will return immediately to the exact
hour 1 hour 00 min).
If the display is 01 - 29 min, the display will go back to 0 min.
If the display is 30 - 59 min, the display will advance to 0 min.
[Example] ADO5164C 1
IO:29 + IO:00 (return to exact hour)
IO:30 -+ II:00 (advances to exact hour)
11 .14.3 PRECAUTIONS WHEN USING

l For safety reasons, when operating keep the sound to a level
where you can enjoy the sound but still hear the sound from
outside vehicles.
l If water gets inside the speaker case or car radio (auto tuning),
it may cause a serious problem, so do not let water get on these
parts.
l Do not wipe the knobs or buttons or any other parts with any
solvent such as benzene or thinner. Always wipe with a soft dry
cloth (in cases of extreme dirt, use alcohol on the cloth).
11.14.4 SPECIFICATION
Tuning method: PLL synthesizer method
Reception frequency: 522 kHz - 1629 kHz
Intermediate frequency: 450 kHz
Rated output: 3 W
Max. output: 5 W
Voltage: DC26.4V (21.6V, 31.2V) (-1 ground
Current: Max. 2A
Outside dimensions: Width 178 mm (7.01 in), height 50 mm (I.97 in),
depth 110 mm (4.33 in)
Weight: 640 g (1.41 lb)
2-37
11 .15 HANDLING AIR CONDITIONER

11.15.1 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. (RECIRCI
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.
l Press switch 0.
l Place levers 01 and (Q in the position shown in the diagram.
l Set switch @I to the desired position.
Cooling (FRESH)
If the air inside the cab is no longer fresh, set FRESH/RECIRC
selector lever (11 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
sI’ to RECIRC again. This increases the cooling effect.
2-38
11.15.2 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.
d4 AD051628
Heating IRECIRC)
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.
l Place levers 1 and 4 in the position shown in the diagram.
0 Set switch : tg the desired position.
AD051629
Heating (FRESH)
If the air inside the cab is no longer fresh, set FRESWRECIRC
selector lever I 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.
AD05162A
REMARK
If the cab is not heated up sufficiently, turn FRESH/RECIRC
selector lever I back to RECIRC. This increases the heating effect.
Dehumidifying and heating

Push switch 2 . When temperature control lever @ 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 temperature.
2-39
11.15.3 PRECAUTIONS 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 running the air conditioner for a long time, turn the lever
to the FRESH position once an hour to carry out ventilation and
cooling.
Be careful not to make the temperature in the cab too low.

l When the cooler is on, set the temperature so that it feels slightly
cool when entering the cab (5 - 6°C 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

l 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 tempera-
tures.)
If this happens, turn the vent fully to the rear and raise the air
conditioner temperature setting slightly.
11.15.4 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
iubricated parts of the compressor. (Run the engine at low speed and
set the temperature control 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 - 6.5 C.
2-40
11.15.5 PROCEDURE FOR REPLACING RECEIVER

Replace the receiver once every two years.
After replacing the receiver, add compressor oil. Turn the re-
ceiver at an angle and measure the oil remaining inside the receiver,
then add the same amount of oil (Denso Oil 8) to fill the receiver.
REMARK
Depending on the condition of use, the replacement interval may
be shorter.
REMARK
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 replacing receiver

l 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
wrth refrigerant.
l When removing the refrigerant from the refrigerant circuit, re-
Icd:,t if ilratltially from the low pressure side to prevent oil from
flr,wllIg out.
11.15.6 CLEANING AIR FILTER

If the air filter for the FRESH or RECIRC air intake becomes
clogged, the cooling or heating capacity will drop. To prevent this,
clean I~F! ;ji!- filter with compressed air once a week.
For detcliis of tht? cleaning method, see “24.1 WHEN REQUIRED”.
2-41
11 .I6 HANDLING HEATER

11.16.1 METHOD OF OPERATION

To heat quickly
Set the switches to the position shown in the diagram on the
right to carry out heating quickly.
l Set FRESH/RECK selector lever (1‘) and temperature control
lever 3 to the position in the diagram on the right.
l Set blower switch P 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 ,.‘!I to the FRESH position.
In this position, the inside of the cab is pressurized to prevent
the entry of dust.
Normal use
Set each switch to the desired position.
11.16.2 CLEANING AIR FILTER

If the air filter for the FRESH or RECIRC air intake becomes
clogged, the heating capacity will drop. To prevent this, clean the air
filter with compressed air once a week.
For details of the cleaning method, see “24.1 WHEN REQUIRED”.
2-42
12. OPERATION
12.1 CHECK BEFORE STARTING ENGINE
12.1.1 WALK-AROUND CHECK
g WARNING
l 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.
l 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.
Before starting the engine, look around the machine and under
the machine to check for loose nut or bolts, or leakage of oil, fuel,
or coolant, and check the condition of the work equipment and
hydraulic system. Check also for loose wiring, play, and collection
of dust at places which reach high temperatures.
Always carry out the items in this section before starting the
engine each day.
6 AM086460
This handrail must not 6

be used for getting on \
or off the machine.
This handrail must not ?%YP,

be used for getting on 4
-\ ‘4 *
or off the machine. 5 AM086470
2-43
1. Check for damage, wear, play in work equipment, cylinders,
linkage, hoses
Check that there are no cracks, excessive wear, or play in the
work equipment, cylinders, linkage, or hoses. If any abnormality
is found, repair it.
2. Remove dirt and dust from around engine, battery radiator

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

Check that there is no leakage of oil from the engine or leakage
of water from the cooling system. If any abnormality is found,
repair it.
4. Check for 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.
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.
7. 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.
8. Check for damage to seat belt and mounting clamps

Check that there is no abnormality in the seat belt or mounting
clamps. If there is any damage, replace with new parts.
2-44
12.1.2 CHECK BEFORE STARTING
Always carry out the items in this section before starting the
engine each day.
CHECK COOLANT LEVEL, ADD WATER
A WARNING
Normally, do not open the radiator cap. When checking the
cooling water level, check the sub-tank when the engine is cold.
1. Open the engine side cover on the left side of the chassis, and
check that the cooling water is between the FULL and LOW
marks on sub-tank ,‘.jj. If the water level is low, add water to the
FULL level through the water filler port in sub-tank 0.
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 addirlg water, close the engine side cover.
AM086490
CHECKING WITH MACHINE MONITOR Machines equipped with canopy

I. Turn starting switch a to the ON position.
2. Check that ail monitor lamps light up for 3 seconds, the warning
!amp lights up for 2 seconds, and the alarm buzzer sounds for
1 second.
REMARK
I IO
l If the lamps do not light up, there may be a failure or disconnec-
tion in the monitor, so please contact your Komatsu distributor. Machines equipped with cab
l When carrying out the checks before starting, do not relay only
on the monitor. Always carry out all the items listed for periodic
maintenance.
I I .
AM086510
OFF
- START
ADO52290
2-45
12. OPERATION
CHECK FUEL LEVEL, ADD FUEL

a WARNING ^
When adding fuel, never let the fuel overflow. This may cause
a fire. If you spill fuel, thoroughly clean up any spillage.
1. Turn the engine starting switch to the ON position and check the
fuel level with fuel level gauge :c$ on the monitor panel.
After checking, turn the switch back to the OFF position.
2. After completing work, fill the fuel tank through oil filler port (0.
For details of the method of opening and closing the cap, see
“11.9 CAP WITH LOCK”.
For details of the fuel to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
3. After adding fuel, tighten the cap securely.
Fuel capacity: 410 e (108 US gal, 90 UK gal)
CHECK FUEL LEVEL, ADD FUEL

a WARNING
1. Removed the cap and check the fuel level using fuel gauge @
2. After completing work, fill the fuel tank through oil filler port @.
For details of the fuel to use, see “20. USE OF FUEL, COOLANT
Fuel capacity: 410 .f (108 US gal, 90 UK gal)
2-46
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
1. Open the engine side cover on the left side of the chassis.
2. Remove dipstick I(;: 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.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
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
When checking the oil level after the engine has been operated,
AD052340
wait for at least 15 minutes after stopping the engine before check-
ing.
If the machine is at an angle, make it horizontal before checking.
CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL

1. Remove dipstick G , and wipe the oil off with a cloth.
2. Insert dipstick i; fully in the oil filler pipe, then take it out again.

G.
F.
4. If ttle oil is above the H mark, drain the excess engine oil from
drain piug :P., and check the oil level again.
ADO52340
5. If the oii level is correct, tighten the oil filler cap securely.
REMARK
l ‘When stopping the engine, check the oil level.
l Wheo checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
L I Ier I\I n !_i
if the nlachine is at an angle, make it horizontal before checking.
2-47
CHECK BRAKE PEDAL TRAVEL
70-90 mm (2.8-3.5in)
1. Depress the brake pedal all the way until it stops.
2. The distance of travel at the center of the pedal (position in the
diagram on the right) should be 70 - 90 mm (2.8 - 3.5 in).
3. When this value exceeds 90 mm (3.5 in), or the brake fails to
work, please contact your Komatsu distributor for adjustment.
AM086570
CHECK DUST INDICATOR

Open the engine side cover on the left side of the chassis, and
check that the red piston has not appeared in the transparent
portion of dust indicator I.
If the red piston has appeared, clean or replace the element
immediately.
For details of the method of cleaning the element, see “24.1
WHEN REQUIRED”.
After checking, cleaning, and replacing, press the knob of dust
indicator 1, to return the red piston to its original position.
I AD052091
CHECK THAT LAMPS LIGHT UP

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.
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
CHECK BACKUP ALARM SOUND
CHECK SEAT BELT FOR WEAR OR DAMAGE

Check the belt and mounting clamps, and if they are worn or
damaged, replace the seat belt.
CHECK FOR WATER AND SEDIMENT IN WATER

SEPARATOR, DRAIN WATER
The water separator separates water mixed in the fuel. If float (3
is at or above red line 1 , drain the water according to the following
procedure:
i. 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 filter. See “24.5
EVERY 500 HOURS SERVICE”.
v AEOS2240
2-48
-- 12. OPERATION
12.1.3 ADJUST OPERATOR’S SEAT
l Adjust the seat position at the beginning of each shift or
l Adjust the seat so that the brake pedal can be depressed all
the way with the operator‘s back against the backrest.
Fore-aft adjustment of seat

Move lever ~I to the right set the seat to a position where it is
easy to operate, then release the lever.
Fore.aft adjustment: 160 mm (6.3 in) (9 stages)
Adjusting cushion
Turn knob ,? to adjust the cushion to the desired strength.
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.
AM086600
2-49
12.1.4 OPERATIONS AND CHECKS BEFORE STARTING
ENGINE
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
1. Check that the brake pedal is locked with parking lever 0. If this
lever is not at the LOCK position, the engine will not start.
AM066250
2. Check that speed range display window @ shows 1st.
3. Check that joystick <$‘iis at the neutral position.
2-50
4. Check that the blade is lowered to the ground and that blade
control lever ,$: is at the HOLD position.
5. Check that the safety lever & is locked.
2-51
12. OPERATION
12.2 STARTING ENGINE Machines equipped with cab
12.2.1 NORMAL STARTING
area, then sound the horn and start the engine.
NOTICE
Do not keep the starting motor rotating continuously for more Machines equipped with canopy
than 20 seconds.
If the engine will not start, wait for at least 2 minutes before
trying to start the engine again.
1. Pull fuel control lever 9 to a position midway between the low

idling and full speed positions.
2. Insert the key into starting switch @ and turn the key to the
START position. The engine will start.
3. When the engine starts, release the key in starting switch 0. The
OFF
key will return automatically to the ON position. I
START
I - Am52291
2-52
12.2.2 STARTING IN COLD WEATHER Machines eauimed with cab
When starting in low temperatures, do as follows.
r-- A WARNING
I
I Never use starting aid fluids as they may cause explosions.
I
NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine fails to start, repeat steps 2 and 3 after waiting for
about 2 minutes.
l-7-- -L--1
AM087330
‘I . Pull fuel control lever CJ>to a position midway between the low
idling and full speed positions.
2. Insert the key into starting switch ;?‘;and turn the key to the ON
OrF
position
ON
- START
AD052290
3. Carry CJIJTpreheating.
T!~?rc, ars ?he following two ways of carrying out preheating.
First l,J:;ethe convenient automatic preheating system.
2-53
0 Automatic preheating
(I) Turn glow switch 3’ to the AUTO position.
When it is turned to the AUTO position, preheating is automati-
tally carried out according to the ambient temperature. Lamp C&
lights up during the preheating operation. When the preheating
is completed, lamp ,4 will go out.
A0052380
J
(2) When the preheating is completed, turn the key in starting switch
OFF
T to the START position to start the engine.
I
START
AD052390 1
~~___
---
(3i After starting the engine, return glow switch Q, to the OFF
position. r-
n
REMARK
If the engine can not start after automatic preheating, start it
using manual preheating.
AD051793
L--.. --
___.-__ --.
0 Manual preheating r----
(1) Turn glow switch ,:3j to position 1 or II. OFF
I
I-amp p, 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 AUTQ
From position II , it will return to OFF
AD051792
The preheating times are as shown below.
Ambient temperature Preheat time
0 c to --5 c
._.. _. ..____._
. .._._.+...__ -
-5 C to --IO c
_.. ..__.._ _.__. ____ +_._‘““““““.-
-10 c to -20 c 30 seconds
_-. .___ - ____-_- ____ ___-___
20 c to -30’ c 45 seconds
--.- I-
If the preheating time is too long or too short, the engine will not
start easily. Observe the correct preheating time.
2-54
(2) When the preheating is completed, turn the key in starting switch
@ to the START position to start the engine.
r OFF
START
I AD052390
4. When the engine starts, release the key in starting switch (2). The
OFF
key will return automatically to the ON position.
I
START
I AD052291
2-55
12,82.3 STARTING IN COLD WEATHER
When starting in low temperatures, do as follows
A WARNING
Never use starting aid fluids as they may cause explosions.
NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine fails to start, repeat steps 2 and 3 after waiting for
about 2 minutes.
I w AM087350 1
1. Pull fuel control lever i to the center position between LOW

IDLING and HIGH IDLING.
2. Insert the key into starting switch !Q,,, turn the key of starting HEAT
switch 7 to the HEAT position and hold it until glow signal 0
glows red.
The preheating times are as shown below.
Ambient temperature Preheat time -START
AM087360
0°C to -5°C
_.___.-..-__
-5°C to -10°C 15 seconds

_--__-
If the preheating time is too long or too short, the engine will not
start easily. Observe the correct preheating time.
3. When glow signal 1% becomes red, turn the key of starting switch
? to the START position and start the engine.
START
AM087370
2-56
4. When the engine starts, release the key in starting switch &. The ’ a
key will return automatically to the ON position.
START
AM088790
2-57
12.3 OPERATIONS AND CHECKS AFTER Machines equipped with cab
STARTING ENGINE
After starting the engine, do not immediately start operations.

First, carry out the following operations and checks.
NOTICE
Avoid abrupt acceleration until warm-up run is completed.
Do not run the engine at low idling or high idling for more than
20 minutes. If it is necessary to run the engine at idling, apply a load Machines equipped with canopy
or run at a medium speed from time to time.
Monitor panel specification

m
I F======%====%
I
1 & AM086820 ]
2
-- P
12.3.1 NORMAL OPERATION

1. Pull fuel control lever QI) 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 run is completed, check gauges and caution

lamps for proper operation. If any abnormality is found, repair
It.
Continue to run the engine at light load until engine water
’ 'AM,,,, (
temperature gauge indicator ,2j falls within the white range
(monitor panel specification) or green range (gauge panel
specification).
3. Check that there is no abnormal exhaust gas color, noise, or

vibration. If any abnormality is found, repair it.
2-58
12.3.2 STARTING IN COLD WEATHER
(Less than 10%)
Pull fuel control lever J to a position midway between 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.
Operate blade control lever ;s’ fully to the RAISE position, then
hold the lever in position, and operate slowly to the left tilt relief I Riaht tilt
and right tilt relief in turn for 5 minutes.

After this, operate the blade control lever 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
io the FLOAT position, hold the lever in position, and relieve the
IeR and right tilt in turn intermittently for 5 minutes.
l.ower the blade to the ground, operate the control lever fully to
the FLOAT position 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.
REMARK
If the work equipment oil temperature has not risen fully, the
response of the work equipment or steering may be slow, or the
lever may become heavy or may not return properly.
Furthermore, if the blade control lever is set to the FLOAT
position and released immediately, the lever may.return to the HOLD
position.
2-59
12.4 MOVING MACHINE
A 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. Note there is _
AM087400
L
an blind spot behind the machine.
When starting on slopes, always keep brake pedal @ de- Machines equipped with cab 1
pressed even after releasing parking lever 0.
When starting the machine on steep uphill slopes, run the
engine at full throttle, keep brake pedal @ depressed, operate
joystick <j’;,to the Fl position, then gradually release the brake
pedal and allow the machine to move off.
1. Set parking lever $i to the FREE position.
2. Operate joystick (4) to the desired position, and check that speed
range display window 1:s shows the correct position.
3. Set safety lever :6! for blade control lever @to the FREE position.
2-60
4. Put blade control lever& in the RAISE position to raise the blade
400 to 500 mm (15, 8 to 19.7 in) off the ground.
Hoid e Raise
5. Move joystick .:q, to the F (forward) or R (reverse) position to

move the machine off.
6. Pull fuel control lever 2. to increase engine speed.
12.5 SHIFTING GEAR

There is no need to stop machine to shift gears.
Set joystick :I’ in the desired position to shift gear.

1st 2nd
AW55366
2-61
12. OPERATION
12.6 SM&NV BETWEEN FORWARD AND Machines equipped with cab
A WARNING -1
When shifting between forward and reverse, for safety reasons

and to reduce shock, stop the machine first, then change the
direction of travel.
1 Machines equipped with canopy
1. Set fuel control lever a to the LOW IDLING position or depress

decelerator pedal ,.2Jito reduce the engine speed.
AMOS7470
2. Depress brake pedal & to apply the brake.

3. Move joystick .:.q! to the N position, depress brake pedal @
further, and stop the machine.
4. Shift joystick :si to the desired position.
5. Pull fuel control lever @ or release decelerator pedal @to raise

the engine speed.
AM087490
2-62
12.7 STEERING MACHINE 1 Machines eauimed with cab
a WARNING,
l 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.
l Never make a pivot turn at high speed.
12.7.1 NORMAL TURNING Machines equipped with canapv
To turn the machine while traveling, incline joystick c’> in the

direction to turn.
___-- -_
0 Turning gradually to left while traveling
If the joystick is pushed forward
forward
and moved partially to the left 1
(L), the steering clutch is disengaged and the machine turns
gradually to the left.
REMARK
When turning gradually to the right, push the joystick forward,
and move it partially to the right.
Do the same when traveling in reverse.
AMOS7000
l I\ilaking sharp turns to left while traveling forward

If the joystick is pushed forward and moved fully to the left (L),
the steering clutch is disengaged, the brake is applied, and the F
machine turns sharply to the left.
REMARK
When making sharp turns to the right, push the joystick forward,
and move it fully to the right.
=,J-_
3*-a. &
P.
AM087010
-
2-63
12.7.2 TURNING WHILE DESCENDING A SLOPE
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.
l Turning gradually to left while traveling forward

If the joystick is pushed forward and moved partially to the right
(R), the machine turns gradually to the left. (Becomes reverse
steering)
REMARK
When turning gradually to the right, push the joystick forward,
and move it partially to the left. (Becomes reverse steering)
AM087020
I
l Making sharp turns to left whle traveling forward

If the joystick is pushed forward 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 joystick forward,
and move it fully, to the right. (Does not become reverse steering)
I AM087030
2-64
12.8 STOPPING MACHINE
Avoid stopping suddenly. Give yourself ample room when

stopping.
When stopping the machine, select flat h&d 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
~~wARNINGl
additional safety measure, thrust the blade into the ground. r Machines eauirmed with canoDv
If the work equipment control lever is touched by accident,
the work equipment may move suddenly, and this may lead
to a serious accident. Before leaving the operator’s seat,
always operate the safety lever to place it securely at the
LOCK position.
i. Depress brake pedal I I to stop the machine.
I AM067540
2. Place joystick i in the N (neutral) position.
N c3 Forward
Reverse4
3. Operate joystick 2, to Ist, and check that speed range display

window 3 shcws the correct position.
ADO55364
2-65
12.9 PRECAUTIONS FOR OPERATION
12.9.1 METHOD OF USING STEERING CLUTCH

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

When operating in water, always keep the bottom of carrier
roller i 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.
AM087070
12.9.3 PRECAUTIONS WHEN TRAVELING UP

OR DOWN HILLS
Use engine as a brake

When going downhill, shift gear shift lever into low speed to run
engine at slow speed and travel down slope using the engine as a
brake.
Never coast down slope with the 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.
12.9.4 PRECAUTIONS ON SLOPES
Be careful of fuel level

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

If the engine stops while working or traveling on a hill, the brake
is automatically applied, move the parking lever to the LOCK position
ta apply the parking brake.
2-66
12. OPERATION
-
12.9.5 IT IS PROHIBITED TO KEEP THE DOOR OPEN

DURING OPERATIONS (MACHINES EQUIPPED
WITH CAB)
Always keep the door closed when traveling or carrying out
operations. If the door is left open, there is danger of damage from
obstacles or strong vibration.
12.9.6 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN

ANY WAY THAT WILL OBSTRUCT THE VIEW
l For safety reasons, do not install anything to the cab glass that
will obstruct the view.
l Always keep the glass clean to ensure safety during operations.
12.9.7 PRECAUTIONS FOR BLIND SPOTS CAUSED BY

CAB STAY
The cab stay cause blind spots

carefully that there is
no obstacle or worker in the surrounding area.
ADO53690
2-67
12.10 PARKING MACHINE Machines equipped with cab
A WARNING
Avoid stopping suddenly. Give yourself ample room when

stopping.
When stopping the machine, select flat hard ground and
avoid dangerous places. If it is unavoidably necessary to park
the machine on a slope, 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. Machines equipped with canopy I
If the work equipment control lever is touched by accident,
the work equipment may move suddenly, and this may lead
to a serious accident. Before leaving the operator’s seat,
always operate the safety lever to place it securely at the
LOCK position.
1. Depress brake pedal @ to stop the machine. I 1
AM087580
2. Place joystick I?. in NEUTRAL position. NQ Forward

Reverse+
3. Operate joystick @ to Ist, and check that speed range display

window G: shows the correct position.
ADO55364
2-68
4. Operate parking lever 5 to lock the brakes.
AM086250
5. Operate blade control lever ~3:to the LOWER position, and lower II
the blade to the ground. Lower h N
MO87120
6. Lock brdde control lever ,.5; with safety lever &.
12.11 CHECK AFTER FINISHING WORK Monitor panel specification

1. Use the meters and caution lamps to check the engine water
temperature, engine oil pressure, fuel level, and transmission oil
temperature.
AM087130
p!!i!@~j AM087140
2-69
12.12 STOPPING ENGINE Machines equipped with cab
NOTICE
If the engine is abruptly stopped before it has cooled down,
engine life may be greatly shortened. Consequently, do not abruptly
stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly stop
it but run it at medium speed to allow it to cool gradually, then stop
it.
1. Place fuel control lever i I;, in the low idling position and run the
engine at low idling speed for about 5 minutes to allow it to
gradually cool down.
7
2. Place fuel control lever il., in the engine stop position and stop
\
the engine.
/
.
r-,/
b
Y
.
%
\ i=Tpl*Mo87
3. Turn the key in starting switch I_?Ito the OFF position and remove
OFF
the key from starting switch $;.
AD0517L)l
2-70
12.13 CHECK AFTER STOPPING ENGINE
1. Walk around the machine and check the work equipment, paint-
work, and undercarriage, and check also for leakage of oil or
water. If any abnormalities are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out
any paper and debris to avoid a fire hazard.
4 Remove any mud stuck to the undercarriage.
12.14 LOCKING
70 prevent vandalism, there are locks at the following places.

Places that can be locked with the starting switch key.
0 Top cover at front of chassis :I..
o Right and left engine side cover $,
0 Battery inspection cover :.$
l Inspection cover for fuel tank drain valve (8
l Cab door opener ,..$ (machines equipped with cab)
l Cap with lock 16
2-71
12.15 WORK POSSIBLE USING BULLDOZER
In addition to the following, it is possible to further increase the

range of applications by using various attachments.
AM087200
12.15.1 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.
When dozing toward one side only, operate with angled blade
(angledozer only).
12.15.2 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.
12.153 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.
12.15.4 FELLING TREES, REMOVING STUMPS

AM087230
NOTICE
Do not up root trees or stumps or fell trees by angling or tilting
the blade.
For trees with a diameter of 10 - 30 cm (3.9 - 11.8 in), raise the

blade high and push 2 or 3 times to fell the tree.
Next, travel in reverse, and dig the corner of the blade into the
ground to cuf arld dig up the roots.
When doing this, never hit the tree at high speed or apply shock
t:; fell the tree.
2-72
12.16 ADJUSTING POSTURE OF WORK
EQUIPMENT
12.16.1 METHOD OF ANGLING BLADE

(ANGLEDOZER ONLY)
Angle the blade when it is needed to dump the soil on one side.
A WARNING
l When adjusting the amount of angling, it is dangerous if the
work equipment is moved by mistake. Set the work equip
ment in a safe condition, then stop the engine and lock the
work equipment securely with the safety lever.
l Be careful when removing, arm 03). After arm 0 is removed
the blade can move freely.
1. Raise the blade 400 - 500 mm (15.8 - 19.7 in) above the ground,
then put blocks under the frame so that the blade does not come
down.
2. Remove pins .I on the left and right sides, then remove arm @
from the frame.
3, insert arm 1.2 into the desired position on the bracket on top of
the frame (3 places on each side), and insert pin 0.
AM087640
J
2-73
1216.2 ADJUSTING AMOUNT OF TILTPOWER TILT
(ANGLEDOZER ONLY)
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 equip
ment securely with the safety lever.
i
NOTICE
The maximum amount of tilt is 400 mm (15.8 in).
Be sure not to exceed 400 mm (15.8 in) for the tilt.
1. Raise the blade 400 - 500 mm (15.8 - 19.7 in) above the ground,
ttlen p:it blocks under the frame so that the blade does not come
down.
2. Loosen set bolt ! of the brace, insert a suitable bar into hole @
of the brace, and turn it.
Right tilt: Make right side shorter, left side longer
Left tilt: Make left side shorter, right side longer
3. Tighten set bolt I .
2-74
12. OPERATION
12.16.3 ADJUST ANGLE OF BLADE EDGE
A WARNING -pI
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 apply the locks
securely to the safety lever.
Adjust the angle (8) of the blade edge to match the type of soil.
1. Angledozer
Adjust the cutting angle by changing the distance (E) between
the joints so that the length of the brace is the same on the left and
right sides.
INCREASE distance MI to INCREASE angle (0)
DECREASE distance (e) to DECREASE angle M.
The standard for the cutting angle (8) is 55”.

I AM067660
The standard for the distance (!J) between the joints is 1127 mm (44.4
in).
2. Power tiltdoter
Turn the brace with bar handle $ and the distance (e) between
the joints to change the cutting angle (Q) as follows.
INCREASE distance (e) to INCREASE angle (0)
DECREASE distance (e) to DECREASE angle (8).
The standard for the cutting angle (8) is 55”.
The standard for the distance (e) between the joints is 1150 mm (45.3
in).
2-75
12. OPERATION
12.17 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.
1217.1 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.
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.
AM087670
When ground inclines to left or right during digging operation,

do not continue to dig with machine inclined. Move machine
back to level ground and start to dig again.
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 obsta-
cles that resist the power of the machine during dozing or
ripping operations.
2-76
12.17.2 INSPECTION AND ADJUSTMENT
l Properly adjust track tension. ClearanceA
Tension should be measured at clearance @ shown in the
diagram - usually 20 to 30 mm (0.8 to 1.2 in) at this point. For
rocky terrain, tighten tracks slightly. In clay or sandy areas,
slightly loosen them. (For inspection and adjustment proce-
dures, refer to “24.1 WHEN REQUIRED”).
l Check idler rollers for oil leakage as well as for loose bolts and
nuts. If any trouble is detected, repair immediately.
l Check the clearance between the idler guide plate and the track
frame. If clearance (EJ increases, idler may develop side motion
and tracks may come off. (For inspection and adjustment proce-
dures, refer to “24.1 WHEN REQUIRED”.)
AM067690
12.17.3 INSPECTION AND REPAIR

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

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

2 links away from master pin. Of length obtained, l/4 is the link
pitch.
REMARK
Basic link pitch (PI: 203 mm (8 in)
Link pitch limit for turning: 206 mm (8.1 in)
There is no link window on the master link.

W4L)
/ _&7-zpyy
I AMo877vl
2-77
MEASURING HEIGHT OF GROUSER (D65El
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)
AD052880
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)x2
Standard size (A): 210 mm (83 in)
Repair limits: 172 mm (6.8 in)
AM087720
2-78
13. TRANSPORTATION
When transporting the machine, observe all related laws and

regulations, and be careful to assure safety.
13.1 LOADING, UNLOADING WORK
A 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.
When loading and unloading the machine, park the trailer on
a fiat firm roadbed. Keep a fairly long distance between the
road shoulder and the machine.
Remove the mud from the undercarriage to prevent the
machine from slipping to the side on slopes.
Be sure the ramp surface is clean and free of grease, oil, ice
and loose materials.
Never change the direction of travel when on the ramps. If it
is necessary to change direction, drive off the ramps and
correct the direction, then drive on to the ramps again. 1 CORRECT / /
When loading or unloading, always use ramps or a platform and

carry out the operations as follows.
Properly apply the brakes on the trailer and insert blocks beneath
the tires to ensure that it does not move. Then fix the ramps in
line with the centers of the trailer and the machine.
Distance between ramps
AW52900
Determine the direction of the ramps, then slowly load or unload
the machine by driving at 1st speed.
Load the machine correctly in the specified position on the

trailer.
2-79
13. TRANSPORTATION
13.2 PRECAUTIONS FOR LOADING, AND

SECURING THE MACHINE
dh WARNING
When the edge of the blade protrudes beyond the trailer, angle
the blade. (Angledozer)
After loading to the specified position, secure the machine as

follows.
Lower the work equipment slowly.
Lock all the control levers securely with the safety lever.
Set the parking lever to the LOCK position.
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.
I
5. For avoiding slip of the machine, secure it tightly as follows.
1) Put blocks ,I, in front and behind the track shoes of both
sides.
2) Set up chain or wire, following (8 or @.
4:: 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 u w AM140300
of the machine, by inserting pads.
6. Confirm that the height of the load clears various limitations on

the way (width and height of tunnels, size of guards, branches
of trees) and meets all laws and regulations governing transpor-
tation.
Refer to “13.3 PRECAUTIONS FOR TRANSPORTATION”.
w w AM140310
2-80
13. TRANSPORTATION
13.3 PRECAUTIONS FOR TRANSPORTATION

WARNING
dh
Determine the route for transporting the machine by taking into
account the width, height and weight of the machine.
I
Obey all state and local laws governing the weight, width and
length of a load. Observe all regulations governing wide loads.
REMARK
In the case of D65P, remove the left and right trunnions.
In the case of D65E, the width including the left and right
trunnions is within 3.0 m, so there is no need to remove them.
In the case of D65E with 3 m semi-U blade, the blade width is
within 3.0 m, so there is no need to remove the work equipment.
1. Remove the left and right trunnions.
2. Tie the tilt hose with a band to prevent it from being damaged.
13.4 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 equipment AM0877M
assemb!y.
AM087760
13.5 REMOVING CAB

If it is necessary to remove the cab for transportation, there is

danger that the seal may be damaged when removing or installing
the cab, so please contact your Komatsu distributor.
2-81
13. TRANSPORTATION
13.6.3 TABLE OF MACHINE WEIGHT

Operating weight (with ROPS & cab)
Model Without work With straight- With straight-
eauioment tiltdozer tiltdozer & riooer
13.6.4 LIFTING PROCEDURE

When lifting the machine, carry out the operations on level
ground as follows.
1. Park the machine at the proper position for the crane, shut down
the engine and apply the parking brake.
2. Set up the sling like wire which is suitable to the load, referring
“13.6.1 POSITION FOR ATTACHING LIFTING POSITION MARKS”
and “13.6.2 SETTING UP WIRE OR ROPE”.
3. Protect the wire from cutting accident, by inserting protective

pads between wire and angular parts of the machine.
4. Choose sledders and bars having sufficient width to prevent wire

from contacting the machine.
5. After wire setting is finished, lift the machine 100 - 200 mm (3.94
- 7.88 in) up from ground, and confirm that wire does not
become loose and the machine is lifted horizontally. Then start
lifting.
2-84
14. COLD WEATHER OPERATION
14.1 PRECAUTIONS FOR LOW TEMPERATURE
If the temperature becomes low, it becomes difficult to start the

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

Change to fuel and oil with low viscosity for all components.
For details of the specified viscosity, see “20. USE OF FUEL,
COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE”.
14.1.2 COOLANT
A WARNING
Keep antifreeze fluid away from an open flame. Never smoke
when using antifreeze.
NOTICE
Never use methanol, ethanol or propanol based antifreeze.
Where no permanent antifreeze is available, an ethylene glycol

antifreeze without corrosion inhibitor may be used only for the cold
season. In this case, clean the cooling system twice a year (in spring
and autumn). When refilling the cooling system, add antifreeze in
autumn, but do not add any in spring.
Absolutely avoid using any water leak preventing agent irrespec-
tive of whether it is used independently or mixed with an antifreeze.
Do not mix one antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant,
see “24.1 WHEN REQUIRED”.
Use a Permanent Antifreeze (ethylene glycol mixed with corro-
sion inhibitor, antifoam agent, etc.) meeting the standard require-
ments as shown below. With permanent antifreeze, no change of
coolant is required for a year. If it is doubtful that an available
antifreeze meets the standard requirements, ask the supplier of that
antifreeze for information.
Standard requirements for permanent antifreeze.
l SAE . . .. . . ... . .. .. . . .. .. . . . .. .. . ... .. . . .. . .. . . .. .. . . .. .. . . . .. . .. .. ..*........................ J1034
l FEDERAL STANDARD .. .. . . .. .. . . .. .. ... . . . .. .. . . .. .. . . . .. .. . . .. . .. . .. . O-A-5480
2-85
14. COLDWEATHEROPERATION
14.1.3 BAlTERY
A WARNING
l To avoid gas explosions, do not bring fire or sparks near the
battery.
l Battery electrolyte is dangerous. If it gets in your eyes or on
your skin, wash it off with large amounts of water, and
consult a doctor.
When the ambient temperature drops, the capacity of the battery

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

from the following conversion table.
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
2-86
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.
l Mud and water on the machine body should be completely
removed. This is to prevent damage to the seal caused by mud
or dirt getting inside the seal with frozen drops of water.
l Park the machine on concrete or hard ground. If this is impos-
sible, park the machine on wooden boards.
l Open the drain valve and drain any water collected in the fuel
system to prevent it from freezing.
l As the battery capacity drops markedly in low temperatures,
cover the battery or remove it from the machine, keep it in a
warm place, and install it again the next morning.
14.3 AFTER COLD WEATHER
When season changes and the weather becomes warmer, do as

follows.
l Replace the fuel and oil for all parts with oil of the viscosity
specified.
For details, see “20. USE OF FUEL, COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE”.
l If for any reason permanent antifreeze cannot be used, and an
ethyl glycol base antifreeze (winter, one season type) is used
instead, or if no antifreeze is used, drain the cooling system
completely, then clean out the inside of the cooling system
thoroughly, and fill with fresh water.
2-87
15. LONG-TERM STORAGE
15.1 BEFORE STORAGE
When putting the machine in storage for more than one month,
do as follows.
After every part is washed and dried, the machine shall be
housed in a dry building. Never leave it outdoors.
In case it is indispensable to leave it outdoors, park the machine
on the flat ground and cover it with canvas etc.
Completely fill the fuel tank, lubricate and change the oil before
storage.
Apply a thin coat of grease to metal surface of the hydraulic

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

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

always add antifreeze to the cooling water.
Place all control levers at the neutral position, operate the safety
lever and parking lever to the LOCK position, then move the fuel
control dial to the low idling position.
15.2 DURING STORAGE
FewaarnNG1
l
If it is unavoidably necessary to carry out the rustpreventive
operation while the machine is indoors, open the doors and
windows to improve ventilation and prevent gas poisoning.
Operate the engine and move the mach,ine for a short distance
once a month so that a new film of oil will be coated over
movable parts and component surfaces. At the same time, also
charge the battery.
l Before operating the work equipment, wipe off the grease on the
hydraulic piston rod.
15.3 AFTER STORAGE
NOTICE
If the machine is stored without carrying out the monthly rust
prevention operation, request your Komatsu distribtitor for service.
Carry out the following procedure when taking the machine out
of long-term storage.
l Wipe off the grease from the hydraulic cylinder rods.

l Add oil and grease to all places.
2-88
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 IF BATTERY IS DISCHARGED
Ai WARNING --
When checking or handling the battery, stop the engine and
turn the starting key to the OFF position before starting.
The battery generates hydrogen gas, so there is danger of
explosion. Do not bring lighted cigarettes near the battery, or
do anything that will cause sparks.
Battery electrolyte is dilute sulphuric acid, and it will attack
your clothes and skin. If it gets on your clothes or on your
skin, wash it immediately off with large amounts of water. If
it gets in your eyes, wash it out with fresh water, and consult
a doctor.
When removing the battery, first disconnect the cable from
the ground (normally, from the negative 0 terminal). When
installing, install the positive @ terminal first. If a tool touches
the cable connecting the positive terminal and the chassis,
there is danger that it will cause sparks.
If the terminals are loose, there is danger that the defective
contact may generate sparks that will cause an explosion.
When installing the terminals, install them tightly.
L
16.2.1 STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:
AM087770
2-89
16. TROUBLESHOOTING
REMOVAL, INSTALLATION OF BATTERY III r\_ 1
Open battery cover ~11, remove 4 bolts ($ on the inside, then

remove cover !,I
Before removing the battery, remove the ground cable (normally
connected to the negative [+ terminal). If any tool touches
between the positive terminal and the chassis, there is danger of
sparks being generated. Loosen the nut of the terminal and
remove the wires from the battery.
When installing the battery, connect the ground cable last.
Insert the hole of the terminal on the battery and tighten the nut.
Tightening torque: 5.9 - 9.8 Nm (0.6 - 1.0 kgm, 4.3 - 7.2 Ibft)
Install battery cover .I,.
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING

BOOSTER CABLE
a WARNING
When starting the engine from another machine, connect the
batteries in parallel.
When connecting the cables, never contact the positive $J
and negative c.9 terminals.
When starting the engine with a booster cable, always wear
safety glasses.
Be careful not to let the normal machine and problem ma-
chine contact each other. This prevents sparks from generat-
ing near the battery which could ignite the hydrogen gas INCORRECT Q I
given off by the battery. If hydrogen gas explodes. It could
cause serious injury.
Make sure that there is no mistake in the booster cable
connections. The final connection is to the engine block of the
problem machine, but sparks will be generated when this is
done, so connect to a place as far as possible from the
battery.
Use care when removing the cables from the machine that
has been started. Do not allow the cable ends to contact each
other or the machine, to avoid hydrogen explosion.
NOTICE
l The size of the booster cable and clip should be suitable for the
battery size.
l The battery of the normal machine must be the same capacity

as that of the engine to be started.
l Check the cables and clips for damage or corrosion.
l Make sure that the cables and clips are firmly connected.
2-90
16. TROUBLESHOOTING
CONNECTING THE BOOSTER CABLES

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

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

1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and keep it to run at high
idling speed.
3. Turn the starting switch of the problem machine to the START

position and start the engine. Refer to “12.2 STARTING EN-
GINE”.
DISCONNECTING THE BOOSTER CABLES

After the engine has started, disconnect the booster cables in the
reverse of the order in which they were connected.
1. Remove one clip of booster cable 1.6)from the engine block of the
problem machine.
2. Remove the other clip of booster cable C@from the negative 0 Engine block of the problem
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 & from the positive @
terminal of the problem machine.
2-91
16. TROUBLESHOOTING
Problem Main causes Remedy
Air conditioner does not work properly l Blown fuse (o Check, repair)
l Insufficient battery charge i ‘Charge
l Defective air conditioner switch (o Replace air conditioner switch)
l Defective blower switch (e Replace blower switch)
l Defective compressor (0 Replace)
Blade pitch does not change even l Defective wiring (o Check, repair)
when pitch operation is carried out l Defective switch (0 Replace)
(pitch specification machines only) l Defective solenoid valve (a Replace)
2-93
16. TROUBLESHOOTING
16.3.2 CHASSIS
When brake pedal is depressed, s Brakes out of adjust, defective brake (o Check, adjust)
machine does not stop oil pressure
Track comes off l Track too loose l Adjust track tension, see WHEN
REQUIRED
Abnormal wear of sprocket l Track too loose or too tightened
Blade, rises slowly, does not rise l Lack of hydraulic oil s Add oil to specified level, see
EVERY 250 HOURS SERVICE.
. ...~________.~_
Does not steer even when l Defective hydraulic pressure (o Check, repair)
steering is operated at steering clutch
-
Noise is generated from idler s Lack of oil in idler l Add oil to specified level.
For details, see WHEN REQUIRED.
--
Blade control lever is not held at FLOAT s Insufficient warming up l Carry out warming up
Transmission oil pressure Wear, scuffing of gear pump (o Check, replace)

does not rise Lack of oil in power train case l Add oil to specified levei.
For details, see CHECKS BEFORE
STARTING.
Element strainer of oil filter in l Clean.
power train case clogged For details, see EVERY ?OOO
HOURS SERVICE.
---_____ _-.-
Lacks drawbar pull (cannot travel s Lack of drive power from engine l See ENGINE RELATED PARTS
at full speed)
.-... _- _
Machine does not move off a Lack of oil in power train case s Add oil to specified level.
when gear shift lever is placed For details, see CHECKS BEFORE
in gear STARTILNG.
l Transmission oil pressure does not l See “Transmission oil pressure
rise does not rise” above
l Steering clutch is slipping (o Check, replace)
0 Wear, scuffing of gear pump
_----- _-
Torque converter overheats l Lack of oil in power train case l Add oil to specified level.
(indicator enters red range) For details, see CHECKS BEFORE
STARTING.
l Transmission oil pressure does not a See “Transmission oil pressure
rise does not rise” above
s Steering clutch is slipping (o Check, replace)
0 Wear, scuffing of gear pump
a Excessive load when operating l Shift down one position, or
reduce the load and increase
the speed when operating.
2-94
16. TROUBLESHOOTlFjG
16.3.3 ENGINE
Engine oil pressure caution l Engine oil pan oil level is low l Add oil to specified level, see CHECK
lamp remains alight when (sucking in air) BEFORE STARTING
engine speed is raised after . Clogged oil filter cartridge l Replace cartridge, see EVERY 250 HOURS
cornpietion cf warm-up SERVICE
l Defective tightening of oil pipe (e Check, repair)
joint, oil leakage from damaged
part
l Defective caution lamp (o Replace lamp)
Steam is emitted from top part Cooling water level low, water Add cooling water, repair, see CHECK
,)f radiator Ipressure valve! leakage BEFORE STARTING
Loose fan belt Adjust fan belt tension, see EVERY 250
HOURS SERVICE
Dirt or scale accumulated in Change cooling water, clean inside of
cooling system cooling system, see WHEN REQUIRED
Clogged radiator fin or damaged Clean or repair, see WHEN REQUIRED
fin
Defective thermostat Replace thermostat)
Indicator cf water temperature Loose radiator filler cap (high Tighten cap or replace packing
gauge IS I” red range on rignt altitude operation)
side of gauge Defective water temperature Replace water temperature gauge)
gauge
Indicator of water temperature l Defective thermostat (o Replace thermostat)

gauge is in white range on left l Defective water temperature (0 Replace water temperature gauge)
side of gauge gauge
._.__.___
_.--.__--_-.-- --_. .-
Engine does not start when . Lack of fuel l Add fuel, see CHECK BEFORE
starting motor is turned STARTING
l Air in fuel system . Repair place where air is sucked in
l Defective fuel injection pump or (* Replace pump or nozzle)
nozzle
l Starting motor cranks engine
.
sluggishly
Glow signal does not glow red
Defective compression
I- See ELECTRICAL SYSTEM
0 Defective valve clearance (0 Adjust valve clearance)

_______-.-- .-___ .--..
Exhaust gas is white or blue l Too much oil in oil pan l Add oil to specified level, see CHECK
BEFORE STARTING
l Improper fuel l Change to specified ‘fuel
Exhaust gas occasionally turns l Clogged air cleaner element l Clean or replace, see WHEN REQUIRED
black . Defective nozzle 10 Replace nozzle)
. Defective compression (o Adjust valve clearance)
Combustion noise occasionally . Defective nozzle (o Replace nozzle)

makes breathing sound
Abnormal noise generated e Low grade fuel being used l Change to specified fuel
(combustion or mechanical) l Overheating l See item “Indicator of water temperature
gauge is in red range on right side of
gauge”.
l Damage inside muffler (e Replace muffler)
l Excessive valve clearance (o Adjust valve clearance)
2-95
MEMO
2-96
MAINTENANCE
17. GUIDES TO MAINTENANCE
Do not carry out any inspection and maintenance operation that is not given in this manual.
Perform maintenance work on hard, fiat ground.
Check service meter

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

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

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for
ambient temperature.
Always use clean washer fluid:

Use automobile window washer fluid and be careful not to let any dirt get into it.
Clean oil and grease:

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

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

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

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

Keep your pockets free of loose objects which can fall out and drop into the machinery; especially when
you work on the machinery while bending over it.
Checking undercarriage:
When working in rocky areas, check for damage to the undercarriage and for looseness, flaws, wear and
damage in bolts and nuts. Loosen the track tension a little when working in such areas.
Cleaning machine:
l Do not direct a high-pressure jet directly at the radiator.
l Do not splash water over the electrical equipment.
3-3
Pre- and post-work checks:

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

Never mix oils of different brands. If you have only oil which is a different brand from the one that is
used in the machine, do not add it but replace all the oil.
Precautions when opening and closing engine side cover:

o When standing on the track to open the engine side cover, adopt a standing position.
l When the engine side cover is open, do not open or close the cab.
Before opening or closing the cab, always close the engine side cover first.
AM087804 AM087810
L INCORRECT
- CORRECT
3-4
18. OUTLINES OF SERVICE
l Use Komatsu genuine parts for replacement.
l When changing or adding oil, do not use a different type of oil.
l Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as
shown in the table below.
Item Kind of fluid
SAE 15W-40
Engine oil pan
API classification CD
Power train case SAE 30

Final drive case , API classification CD
- -_----
SAE 1OW
Hydraulic tank API classification CD
_--_ 1
ASTM D975 No. 2

(However, ASTM 0975 No. 1 is
Fuel tank used for the winter season
(October to March))
Komatsu Super Coolant

Radiator
(AF-ACL) 41% added to water
18.1 OUTLINE OF OIL, FUEL, COOLANT
Oil is used in the engine and work equipment under extremely severe conditions (high temperature,
high pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and
Maintenance Manual. Even if the oil is not dirty, always replace the oil after the specified interval.
Oil corresponds to blood in the human body, so always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from getting in.
The majority of problems with machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit.
In such cases, please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you to have an analysis made of the oil periodically to check the condition of the
machine. For those who wish to use this service, please contact your Komatsu distributor.
3-5
18.1.2 FUEL
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work
properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature
below -15”C), so it is necessary to change to a fuel that matches the temperature.
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.
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.
18.1.3 COOLANT
River water contains large amounts of calcium and other impurities, so if it is used, scale will stick
to the engine and radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.
When using anti-freeze, always observe the precautions given in the Operation and Maintenance
Manual.
Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine
is shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as
it is even in hot areas.
Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.
The proportion of anti-freeze to water differs according to the ambient temperature.
For details of the mixing proportions, see “24.1.1 CLEAN INSIDE OF COOLING SYSTEM”.
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating and will also cause problems with corrosion from
the air in the coolant.
18.1.4 GREASE
l Grease is used to prevent twisting and noise at the joints.

l The nipples not included in the maintenance section are nipples for overhaul, so they do not need
grease.
If any part becomes stiff after being used for a long time, add grease.
l Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe
off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating
parts.
3-6
18.1.5 STORING OIL AND FUEL
l Keep indoors to prevent any water, dirt, or other impurities from getting in.
l When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum
can is at the side. (To prevent moisture from being sucked in)
If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures
to protect them.
l To prevent any change in quality during long-term storage, be sure to use in the order of first in -
first out (use the oldest oil or fuel first).
18.1.6 FILTERS
l Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from
entering important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, it is necessary to consider replacing the filters at
shorter intervals according to the oil and fuel (sulfur content) being used.
l Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
l When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles
are found, please contact your Komatsu distributor.
o Do not open packs of spare filters until just before they are to be used.
l Always use Komatsu genuine filters.
18.2 RELATING TO ELECTRIC SYSTEM
l If the wiring gets wet or the insulation is damaged, the electric system leaks and this could result
in hazardous malfunction of the machine.
l Services reiating to the electric system are (I) check of fan belt tension, (2) check of damage or wear
in the fan belt and (3) check of battery fluid level.
l Never remove or disassemble any electric components installed in the machine.
l Never install any electric components other than these specified by Komatsu.
l Be careful to keep the electric system free of water when washing the machine or when it rains.
l When working on the seashore, carefully clean the electric system to prevent corrosion.
l Never connect any optional power source to the fuse, starting switch, battery relay, etc.
3-7
19. WEAR PARTS LIST
Wear parts such as the filter element, cutting edge, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
The parts in parentheses are to be replaced at the same time.
Weight Replacement
item Part No. Part Name Q’ty
(kg) frequency
07063-01054 Element 1
Power train filter
(07000-72100) (O-ring) (1) Every 250 hours
sevice
Engine oil filter (D65P) 600-211-1230 Cartridge 1
Engine oil filter (D65E) 6136-51-5120 Cartridge 1

- Every 500 hours
service
Fuel filter 600-31 l-8292 Cartridge 1
Every 1000 hours

Corrosion resistor (D65P) 600-41 l-l 150 Cartridge 1
service
07063-01100 Element 1 Every 2000 hours

Hydraulic oil filter
(07000-02 135) (O-ring) (1) service
6128-81-7032 Element ass’y 1

Air cleaner
600-181-4300 Outer element ass’1 - 1
Electrical intake air heater 6150-11-4820 Gasket 2
14x-71-11310 Cutting edge 38.4 2

Blade 144-70-11251 End bit (left) 1
144-70-l 1261 End bit (right) 1
[ D:eFdozer ] (02090-l 1270) (Bolt) (28)
(02290-l 1219) (Nut) (28)
14Y-71-11210 Cutting edge 45.5 2

Blade 13F-Z27- 1582 End bit (left) 1
D65P 13F-227-1572 End bit (right) 1
- Tiltdozer
I . Tilt pitch dozer 1 (02090-l 1270)
(02290-I 1219)
(Bolt)
(Nut)
(32)
(32)
144-70-I 1131 Cutting edge 45.5 2

Blade 144-70-I 1251 End bit (left) 1
D65E 144-70-I 1261 End bit (right) 1
. Angledozer (02090-l 1270) (Bolt) (32)
I
(02290-I 1219) (Nut) (32)
3-8
19. WEAR PARTS LIST
Weight Replacement
Item Part No. Part Name
(kg) Q%’ frequency
130-72-41130 Cutting edge 37.5 1

130-920-2 180 Cutting edge 34.0 1
Semi-U blade 175-71-22272 End bit (left) 39.0 1
175-7 l-22282 End bit (right) 39.0 1 -
[ ?z:dozer ] (02090-l 1270) (Bolt) (17)
(02290-l 1219) (Nut) (17)
(02090-l 1495) (Bolt) (14)
(02290-l 1422) (Nut) (14)
14X-952-1 270 Cutting edge 29.8 2

Semi-U blade (3 m) 150-70-21356 End bit (left) 26.2 1
[ D65E i 150-70-21346 End bit (right) 26.2 1
/ Tllidorer I (02090-l 1285) (Bolt) (12)
(02090-l 1270) (Bolt) (14)
(02290-11219) (Nut) (26)
NOTICE
When handling parts that weight more than 20 kg, remember that they are heavy objects, and take
the necessary care.
3-9
20. USE OF FUEL, COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
RESERVOIR
KIND OF
,
AMBIENT TEMPERATURE
-T- CAPACITY
FLUID 14 32 50 68 86 104’ F Specified Refill
) . -10 0 10 20 30 40’1C
-
I---
44 e 38 e
Engine oil pan 11.6 US gal 10.0 US gal
9.7 UK gal 8.4 UK gal
-
75 e 50 e
Power train case 19.8 US gal 13.2 US gal
(D65E)
‘D2645eE’
6.3 US gal
24 e
6.3 US gal
Engine oil 5.3 UK gal 5.3 UK gal
(D65P)
‘D2675ep’
7.1 US gal
27 e
7.1 US gal
-
95 e 55 e
Hydraulic system 25.1 US gal 14.5 US gal
-
0.15 e 0.15 e
Idler (each) 0.04 US gal 0.04 US gal
m
- I I I I I
410 e
Fuel tank Diesel fuel - 108.2 US gal
-
- z
.-.
I I I 1 ,
90.2 UK gal
58.2 e
Cooling system Water 15.4 US gal
4dd antifreeze
(incl. sub-tank) 12.8 UK gal
z ASTM D975 No. 1
3-10
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENTTEMPERATURE
REMARK
l When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
’ Change interval of oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0% l/2 of regular interval

--
Above 1.0% l/4 of regular interval
l When starting the engine in an atmospheric temperature of lower than O’C, be sure to use engine
oil of SAElOW, SAEIOW-30 and SAE15W-40, even though an atmospheric temperature goes up to
10°C more or less in the day time.
e Use API classification CD as engine oil and if API classification CC, reduce the engine oil change
interval to half.
l There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, 15W-40), but be
sure to add single grade oil that matches the temperature in the table.
l We recommend Komatsu genuine oil which has been specifically formulated and approved for use
in engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
3-11
20. USE OF FUEL, COOLANTAND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Engine Oil
Anti-freeze
[CD or CEI
Coolant
SAElOW, 30, 40 Gear Oil Grease
JO. Supplier [Ethylene Glycol
1ow30, 15w40 [GL-4 or GL-51 [Lithium-Base]
Base1
(The 15W40 oil SAEBO, 90, 140 NLGI No. 2
Permanent Type
marked * is CEJ
EOlO-CD AF-ACL
EOBO-CD GO90 G2-LI AF-PTL
1
KoMATSU EOlO-30CD GO140 GZ-LI-S AF-PT (Winter, one
E015-40CD season type
Diesel sigma S
Super dieselmulti-
2 AGIP Rotra MP GR MU/EP
grade
*Sigma turbo
Multi-purpose gear RYKON prenium

3 AMOCO *Amoco 300
oil grease
Litholine HEP 2
4 ARC0 *Arcofleet S3 plus Arco HD gear oil
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
*RPM delo 400 Universal thuban Marfak all purpose 2

6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hvpoy Anti-freeze
Spheerol EPLP
CRD HVP~Y B
HYP~Y C
8 CHEVRON lDelo 400 Universal gear Ultra-duty grease 2
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease
lubricant
Multiperformance 3C Tranself EP
10 ELF Glacelf
Performance 3C Tranself EP type 2
Essolube D3
lEssolube XD-3
EXXON Gear oil GP
*Essolube XD-3 Extra Beacon EP2 All season coolant
” (ESSO) Gear oil GX
lEsso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gdar Gulfcrown EP2 Antifreeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolanl
Delvac 1300 Mobilux EP2

Mobilube GX
13 MOBIL lDelvac super Mobilgrease 77
Mobilube HD
low-30, 15w-40 Mobilgrease special
3-12
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Engine Oil
Anti-freeze
[CD or CEI
Coolant
SAElOW, 30, 40 Gear Oil Grease
No. Supplier [Ethylene Glycol
lOW30, 15w40 [GL-4 or GL-51 [Lithium-Base]
Base1
(The 15W40 oil SAE80, SO, 140 NLGI No. 2
Permanent Type
marked * is CE.)
Multi-purpose white
*Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White - bearing summer coolant
grease
15 1 PETROFINAI FINA kappa TD / LIE: ~~~~~~~/E / FINA marson EPLP / FINA tamidor
Spirax EP -
16 SHELL Rimula X Alvania EP grease
Spirax heavy duty I
*Ursa super plus

18
Ursa premium
Total EP
Rubia S
19 TOTAL Total transmission Multis EP2 Antigel/antifreeze
*Rubia X
TM
20 UNION lGuardol MP gear lube LS Unoba EP
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B Antifreeze
MDC Multigear C
3-13
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND
NUTS
21 .I INTRODUCTION OF NECESSARY TOOLS

The following tools are needed when carrying out maintenance.
No. 1 Name of tool 1 Part No. Remarks
1 1 Wrench set 09000-30006 Applicable width across flats (Sl - S2)

8mm-10mm,12mm-14mm
I
13 mm - 17 mm, 19 mm - 22 mm
s2
24 mm - 27 mm, 30 mm - 32 mm AD053370
----I
2 Screwdriver 09033-00190 Interchangeable flat-head and cross-head type
__------__---
3 Socket wrench set
+ 09020-10285 Applicable width across flats
10 mm, 13 mm
14 mm, 17 mm
19 mm, 22 mm, 24 mm,
Extension, Handle
_-._ -L---- -I- -
1
4 Socket 09021-03653 Applicable width across flats 36 mm for mounting trunnion
__-. -- _.-.---_-
5 Handle 09024-00300
.__. t ..-
6 Filter wrench 090 19-08035 For filter cartridges
- _--
7 Socket 09084-01422 For corrosion resistor (D65P)
--____-.--~~~-~
8 Grease pump 07952-70002 For greasing work
----
9 Grease cartridge 07950-90403 (Lithium base grease, 400 g)
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 battery inspection
cover on the left side of the machine. See “11.13 TOOL BOX”.
3-14
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
21.2 TORQUE LIST
Unless otherwise specified, tighten the metric bolts and nuts to

the torque shown in the table.
The tightening torque is determined by the width across the flats
.ts of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu
genuine part of the same size as the part that was replaced.
Nm (newton meter): 1Nm 9 0.1 kgm
+ 0.74 lbft
TIifeati diarneter Mdth across

of tJoh (mm) flat (mm)
--
!a! (b!
Nm k9m Ibti
6 10 13.2 2 1.4 1.35 + 0.15 9.73 + 1.03

8 13 31.4 -c 2.9 3.2 +_0.3 23.2 2 2.1
10 1: 65.7 -c 6.8 6.7 f 0.7 48.5 2 5.0
12 ‘I9 112 + 9.8 11.5 + 1.0 82.6 + 7.2
14 22 177 + 19 18.0 + 2.0 131 + 14
__ ~..._____...
-_. _... _ _.-- -
16 24 279 + 29 28.5 + 3 206 + 21
18 27 383 t 39 39 + 3 282 2 29
20 30 549 _+58 56 -c 6 405 * 43
22 32 745 + 78 76 5 8 549 2 58
24 36 927 2 98 94.5 * IO 684 + 72
._ .__--- - ..------
27 41
30 46
33 50
36 55
39 60
NOTICE
When tightening panels or other parts having tightening fix-
tures made of plastic, be careful not to use excessive tightening
torque: doing so will damage the plastic parts.
3-15
To ensure safety at all times when operating or driving the machine, the user of the machine must
always carry out periodic maintenance. In addition, to further improve safety, the user should also carry
out periodic replacement of the parts given in the table. These parts are particularly closely connected
to safety and fire prevention.
With these parts, the material changes as time passed, or they easily wear or deteriorate. However,
it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always
be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that
they always maintain their function completely.
However, if these parts show any abnormality before the replacement interval has passed, they
should be repaired or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at
the same as the hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same
time.
Ask your Komatsu distributor to replace the critical parts.
No. Safety critical parts for periodic replacement O’ty Replacement interval
1 Fuel hose (fuel tank - injection pump) 1

- ._-._ -.- __.__.._____
2 Fuel hose (injection pump - fuel filter) 2
3 Fuel return hose (injection pump - fuel tank) I I I
-.“t-.-_-- .------+
Fuel return hose (injection nozzle - fuel tank)
5 Hose (power train strainer - power train pump)
6 Hose (power train pump - power train filter) II 1
7 Hose (power train filter - transmission case)
Hose (transmission case - steering relief valve)

-I- 8
Every 2 years or 4000 hours,
Hose (power train lubrication pump - steering case) 1 whichever comes sooner
Hose (scavenging pump - steering case) 1
11 1 i-lose (torque converter case - transmission oil cooler) ( 1 (
12 Hose (transmission oil cooler - transmission case) I/ 1
13 Brake pressure detection hose 2

I I
14 Steering clutch pressure detection hose 2

---__-.-
15 Transmission modulation pressure detection hose 1
16 Torque converter inlet port pressure detection hose 1
17 Torque converter outlet port pressure detection hose 1

.--__-
18 Seat belt 1 Replace every 3 years
3-16
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
AM087840
3-17
23. MAINTENANCE SCHEDULE CHART
23.1 MAINTENANCE SCHEDULE CHART
SERVICE ITEM PAGE
WHEN REQUIRED
Clean inside of cooling system 3-21
Check, clean and replace air cleaner element 3-25
Check track tension 3-27
Check and tighten track shoe bolts 3-29

-_--- -..--- . .._.__....
-.-- __...
I.--.-.--.-_..__.- _-.-
Check electrical intake air heater 3-29
Reverse and replace the end bits and cutting edges 3-30
Clean, check radiator fins 3-32

------.-_. _-..-. ___.. _..--.._----
Adjust idler clearance 3-33
Adjusting tension of center brace (Power tilt and Power tilt, power pitch dozer onl\j) 3-34
--__.-.--_-.-.-__ -...--___ --..- -.-
Clean air conditioner air filter (FRESHIRECIRC filter) (Machines equipped with cab) 3-35
Check, Adjust air conditioner (Machines equipped with cab) 3-36

_._--_.-.___- .___,_.-.__
Grease door hinge (Machines equipped with cab) 3-36
Check door lock striker (Machines equipped with cab) 3-36
Replace door damper (Machines equipped with cab) 3-37

-- .--.-._ -___.-
Check window washer fluid level, add fluid (Machines equipped with cab) 3-37
Bleed air from head end of right pitch cylinder (Power tilt, power pitch dozer only) 3-37
_---____ -
Replace wiper blade (Machines equipped with cab) 3-38
Check idler oil level, add oil

_-__ --
CHECK BEFORE STARTING
_.______.
Check coolant level, add water 3-40
-..- . .._.__.
_._..---_._
Checking with machine monitor (Monitor panel specification) 3-40
Check fuel level, add fuel (Monitor panel specification) 3-41

--. - ._.-..-- ..-. -_-.-.._--
Check fuel level, add fuel (Gauge panel specification) 3-41
- - .-_---
Check oil level in engine oil pan, add oil 3-42
- . - ---__-.- --____
Check oil level in power train case, add oil 3-42
______.._..__~ _.-.---- -~
Check brake pedal tavel 3-43
----.--- -_--
Check dust indicator 3-43
- .-_-. ---
Check that lamps light up 3-43
- _-.~-- --
Check horn sound 3-43
.- .--- -____--
Check backup alarm sound 3-43
_---.
3-18
SERVICE ITEM PAGE
Check seat belt for wear or damage 3-43

..- __._
-.-_-_.-_--- --
Check for water and sediment in water separator, drain water 3-43
- - _..__..
-- __._._ ~____.
EVERY 50 HOURS SERVICE
Drain water, sediment from fuel tank 3-44

_..__.._.
_.__.....,__._____._._..____.-
Lubricating 3-45
. . ___... .__ .__..__
..___.._..-_..__-__
(Power tilt dozer)
l Lift cylinder support yoke (4 places) 3-45
l Lift cylinder support shaft (2 places) 3-45

__. _ .-. . - _.._
-- ._..._.
-_-.-.------
l Lift cylinder ball joint (2 places) 3-45
l Tilt cylinder ball joint (1 place) 3-45
l Tilt brace ball joint (I place) 3-45

__I_--
l Brace ball joint (2 places) 3-45
l Tilt brace thread (I place) 3-45

----
(Power tilt-power pitch dozer)

-.- .--
l Tilt cylinder ball joint (1 place1 3-46
l Pitch cylinder ball joint (I place) 3-46
l Brace ball joint (2 places) 3-46
(Angledozer)
_-..- ..___ _-_--
-
_-...--_--__ _._------
._..-.-.- .___
- .._. -------
l Tilt brace ball joint (2 places) 3-47
_._-_.- __..-- ..----
l Tilt brace thread (2 places) 3-47
..,. _____....._._.......-
..______._ --_
Grease equalizer bar side pin (4 places) 3-48
_. ___
._-._. __^__.-.------. --
Grease equalizer bar center pin (1 place) 3-48
Check oil level in final drive case, add oil 3-49

_.-..- ._------__--.- -.-_
Check oil level in hydraulic tank, add oil 3-49
.-.- .-_--
Check level of battery electrolyte 3-50
___.-..--.. -...-
Check fan belt tension, adjust 3-51
3-19
SERVICE ITEM PAGE
(EVERY 250 HOURS SERVICE)
Drain water and sediment from fuel filter 3-52
Check, clean additional fuel strainer 3-52
Replace power train oil filter element 3-53
Check brake performance 3-54
Replace fuel filter cartridge 3-55
Change oil in engine oil pan, replace engine oil filter cartridge 3-57

(Power train strainer, scavenging
Change oil in power train case, clean strainers um strainer) 3-59
Change oil in final drive case 3-61
Clean power train (transmission) case breather (1 place) 3-62
Grease universal joint (2 places) 3-62
Replace corrosion resistor cartridge (D65P only) 3-63
Check all tightening parts of turbocharger (D65P only) 3-63
Check play of turbocharger rotor (D65P only) 3-63
Check for loose Rops mount bolts 3-63
Change oil in hydraulic tank, replace hydraulic oil filter element 3-64
Clean, check turbocharger (D65P only) 3-66
Clean engine breather element 3-66
Check vibration damper 3-66
Check alternator, starting motor 3-66
Check engine valve clearance, adjust 3-66
Check water pump 3-67
3-20
24. SERVICE PROCEDURE
24.1 WHEN REQUIRED
24.1.1 CLEAN INSIDE OF COOLING SYSTEM
I g WARNING
Soon after the engine has been stopped, the coolant is hot
and can cause personal injury. Allow the engine to cool
before draining water.
Never be under the machine with the engine running. To
avoid serious injury, always stop the engine before being
under the machine to open the drain valve.
Never remove the radiator cap when the engine is at operat-
ing temperature. At operating temperature, the coolant is
under pressure. Steam blowing up from the radiator could
cause personal injury. Allow the engine to cool until the
radiator filler cap is cool enough to touch with your hand.
Remove the filler cap slowly to relieve pressure.
When removing drain plug, avoid pouring coolant on your-
self.
Antifreeze is flammable, so keep it away from any flame.
l Clean the inside of the cooling system, change the coolant and
replace the corrosion resistor according to the table below.
,_.__ __._____.____._______.___ _
1 Cleaning inside of
Replacing corrosion
Kind of coolant I cooling system and resistor
I changing coolant
._. ._.._.
_...-._. _--.--_- +----__.
Permanent type antifreeze 1Every year (autumn) or
(All season type) ! every 2000 hours
/ whichever ccmes first
____.._.._ __...-A______
Non permanent type Every 6 months (spring, Every 1000 hours and
antifreeze containing autumn) when cleaning the inside
ethylene glycol (Winter, (Drain antifreeze in spring, of the cooling system and
one season type) add antifreeze in autumn) when changing coolant
Every 6 months or every

When not using antifreeze 1000 hours whichever
comes first
___--_-_.-- -- __L._----_---._I
3-21
Use a permanent type of antifreeze.

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

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

temperature in the past, and decide from the mixing rate table
given below.
It is actually better to estimate a temperature about 10°C (50°F)
lower when deciding the mixing rate.
Mixing rate of water and antifreeze
Min. “C -5 -10 -15 -20 -25 -30

atmospheric
temperature “F 23 14 5 -4 -13 -22
e 13.4 17.5 21.0 23.9 26.8 29.1

f I I 1 I I
Amount of
antifreeze US gal 3.54 4.62 5.54 6.31 7.08 . 7.68
UK gal 2.95 3.85 4.62 5.26 5.90 6.40

----
e 44.8 40.7 37.2 34.3 31.4 29.1
Amount of
water US gal 11.82 10.74 9.82 9.05 8.28 7.68
UK aal 9.85 8.95 8.18 7.54 6.90 6.40
l We recommend use of an antifreeze density gauge to control the

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

If river water, well water or other such water suljply must be
used, contact your Komatsu distributor.
3-22
1. Turn radiator cap (1; slowly to remove it.
2. Set a container to catch the coolant under drain valve @ and

drain plug (3;. Open drain valve 8:~)at the bottom of the radiator
and drain plug (3) on the side face of the cylinder block to drain
the water.
3. After draining the water, close drain valve $2) and drain plug 0,
and fill with city water.
4. Open drain valve (2) and drain plug GJ, run the engine at low
idling, and flush water through the system for 10 minutes. When
doing this, adjust the speed of filling and draining the water so
that the radiator is always full.
While flushing water through the system, watch carefully that
the water inlet hose does not come out of the radiator water
filler.
5. After flushing, stop the engine, open drain valve @ and drain
plug 3, then close it again after all the water has drained out.
6. After draining the water, clean with a flushing agent.

When washing, follow the instructions given with the detergent.
7. After flushing, open drain valve ,:?.,and drain plug 0, completely

drain all the water, then close the drain valve and drain plug, and
fill with city water up to near the filler port.
8. \/Vhen the tank is filled to near the water filler port, open drain
valve 3’ and drain plug (g!, start the engine, run at low idling, and
continue the flushing operation until clean water comes out.
Adjust the amount of water flowing in and out to ensure that the
radiator is always full during the flushing operation.
9. When clean water comes out, stop the engine, and close drain
valve :.<, and drain plug ;?I.
10. Add city water until the water overflows from the water filler
port.
11. To remove the air in the cooling water, run for five minutes at
low idling, then for another five minutes at high idling.
(When doing this, leave the radiator cap off.)
3-23
24. SERVICEPROCEDURE
12. Drain the cooling water inside sub-tank 0, clean the inside of the
sub-tank, then fill again with cooling water to a point midway
betwee the FULL and LOW marks.
13. Stop the engine, wait for 3 minutes, and city water until the water
level reaches near the water filler port, then tighten the cap.
AM066490
3-24
24.1.2 CHECK, CLEAN AND REPLACE AIR CLEANER

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

glasses or goggles to protect the eyes.
Checking
Whenever the red piston in dust indicator @j appears, clean the
air cleaner element.
Cleaning or replacing outer element

1. Loosen bolt .2:, remove cover $I and the outer element.
2. Clean the air cleaner body interior and the dust cup.
3. Direct dry compressed air (less than 700 kPa (7 kg/cm2, 100 psi))
to the element from inside along its folds, then direct it from
outside along its folds and again from inside.
I) Remove one seal from the outer element. The number of
times the outer element has been cleaned can be seen by the
number of removed seals.
2) Replace the outer element which has been cleaned 6 times
repeatedly or used throughout a year. Replace the inner
element at the same time.
3) Replace the element when the dust indicator red piston
appears soon after installing the cleaned element even though
it has not been cleaned 6 times.
4) Check inner element mounting nuts for looseness and, if
necessary, retighten.
5) Replace seal washer ($ or wing nut @ with new parts if they
are broken.
6) Remove evacuator valve @) and clean with compressed air.
After cleaning, install it.
3-25
NOTICE
If small holes or thinner parts are found on the element when
it is checked with an electric bulb after cleaning and drying, replace
the element.
Do not use an element whose folds or gasket or seal are
damaged.
When cleaning the element, do not hit it or beat it against
something.
AD053040
4. Set the cleaned element and cover i&j.
Replacing inner element

1. First remove the cover and 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.
4. Fit a new inner element to the connector and tighten it with nuts.
Do not clean and reinstall a inner element.
5. Install the outer element and the cover.
6. After replacing the element, return the red piston in the dusl
indicator to its original position.
3-26
24.1.3 CHECK TRACK TENSION

The wear of pins and bushings on the undercarriage will vary
with the working conditions and soil properties. It is thus necessary
to continually inspect the track tension so as to maintain the stand-
ard tension.
Carry out the check and adjustment under the same conditions
as when operating (on jobsites where the track becomes clogged
with mud, measure with the track clogged with mud).
INSPECTION
Stop the machine on level ground (stop with-the transmission in
FORWARD without applying the brake). Then place a straight bar on
the track shoes between the carrier roller and the idler as shown in
the figure, and measure the clearance between the bar and the
grouser at the midpoint. If the clearance is 20 - 30 mm (0.79 - 1.18
in), the tension is standard.
If the track tension is not at the standard value, adjust it in the
1890
following manner.
ADJUSTMENT
A WARNING
Grease inside the adjusting mechanism is under high pressure.
Grease coming from lubricator 0 under pressure can penetrate
the body causing injury or death. For this reason, do not loosen
lubricator ‘\I_‘more than one turn. Do not loosen any part other
AM087900
than lubricator Q:. Furthermore, do not bring your face in front I
of the grease fitting.
If the track tension is not relieved by this procedure, please
contact your Komatsu distributor.
0 When increasing tension

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

is still loose, the pin and bushing are excessively worn, so they
must be either turned or replaced. Please contact your Komatsu
distributor.
3-27
l When loosening tension
relieved by this procedure, please contact your Komatsu dis-
1. Loosen lubricator c$ gradually to release the grease.
2. Turn lubricator 0 a maximum of one turn.
3. If the grease does not come out smoothly, move the machine
backwards and forwards a short distance.
4. Tighten lubricator 0.
5. To check that the correct tension has been achieved, move the
machine backwards and forwards.
6. Check the track tension again, and if the tension is not correct,
adjust it again.
3-28
24.1.4 CHECK AND TIGHTEN TRACK SHOE BOLTS

If the machine is used with track shoe bolts <i loose, they will
break, so tighten any loose bolts immediately.
0 Method for tightening (shoe bolt)

1. First tighten to a tightening torque of 392 + 39 Nm (40 + 4 kgm,
289 r 29 Ibft)) then check that the nut and shoe are in close
contact with the link contact surface.
u5 AM087920
2. After checking, tighten a further 120 + 10”.
0 Method for tightening (master link connecting bolt)

1. First tighten to a tightening torque of 343 f 39 Nm (35 f 4 kgm,
253 +. 29 Ibft) then check that the link contact surfaces are in close
contact.
2. After checking, tighten a further 180%.
Order for tightening

Tighten the bolts in the order shown in the diagram on the right.
24.1.5 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.
3-29
24.1.6 REVERSE AND REPLACE THE END BITS AND
CUTI-ING EDGES
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
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 safety lever to the LOCK position.
3 Measure the wear of the end bit and cutting edge in accordance
wit11 the wear standards given below.
Wear standards Unit: mm (in)
Item Judgement standard

_..___. ..-- .._--.-- ,. I
I
Work Standard
No. Measurement point Repair limit
equipment dimension
1 Height of outside ’ A
..-._- __
237 (9.3) 204 (8.0)
of end bit
t S. c 204 (8.0) 187 (7.4)
t------
}-_--o__ 292 (I 1.5) 254 (10.0)
I__. -L.._ 315 (12.4) 254 (10.0)
237 (9.3) 204 (8.0)

. _.,_.- ._ .._ ..__i ._+-__
2 Width of and oit / 325 (12.8) 300 (Il.81
t---rc 325 (12.8) 300 (11.8)

i._-__,.-_- .--
T35 (17.1) 410 (16.2)
515 (20.3)
________
310 (12.2)
__i.
3 Height of inside 187 (7.4)
of end brt
187 (7.4)
254 (10.0) 237 (9.3)

..-._- . -. ---
254 (10.0) 237 (9.3)
/__.-.--.
204 3.0, 187 (7.4)
_ .._ __ _ __.-. _I __.F_. - -..-- _._--_
b Height of cutting j
+.___
A
_
102 (4.0)
__.-
85 (3.3)
erlg!: rfr:m center
of bolt mounting 102 14.0) 85 (3.3)
ho:,: to end face) 127 (5.01 103 (4.1)
!_.._._E 102 (4.01 85 (3.3)

i F 102 (4.0) 85 (3.3)
_-.-- .I
The symbols in the work equipment column have the following

meaninq.
A: Straight tiltdozer (D65E)
B: Straight tiltdozer (D65P)
c: Power tilt, power pitch dozer (D65E)
D: Semi-U blade (3 m) (D65E)
E: Semi-U blade (D65E)
F: Angledozer (D65E)
3-30
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.
5. Reverse or replace the cutting edge and the end bit when worn
out.
Nut tightening torque:

Straight tiltdozer 461 -f: 69 Nm
(47 + 7 kgm, 340 + 51 Ibft)
Power tilt, power pitch dozer 461 + 69 Nm
(47 + 7 kgm, 340 + 51 Ibft)
Semi-U blade 461 + 69 Nm
(47 + 7 kgm, 340 = 51 Ibft)
Angledozer 441 + 49 Nm
(45 f 5 kgm, 325 + 36 Ibft)
If bolt I. and nut :2,1 are damaged, replace them with new ones
at the same time.
6. After several hours of running, retighten the nuts.
3-31
24.1.7 CLEAN, CHECK RADIATOR FINS
g WARNING
If compressed air, steam, or water hit your body directly, there
is danger of injury. Always wear protective glasses, mask, and
safety shoes.
If the radiator fins are clogged or dirty, clean and inspect them.
1. Remove bolts <!; (4 bolts).
2. Open the A side (hinge side) of the radiator mask.

It opens approx. 10 mm (0.4 in).
3. Leave the B side of the radiator mask open.
4. Clean the radiator fins clogged with mud, dust and leaves with
compressed air. Steam or water may be used instead of com-
pressed 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.
5. When closing the radiator mask, always push in the A side first,
then push in the B side, align the bolt holes, and tighten bolt 0.
3-32
24.1.8 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 proce-
dure.
AM097970
ADJUSTMENT
1. Drive the machine on level ground for I- 2 m (3.28 - 6.56 ft), then
remove the covers (both inside and outside) at the side face of
the idler.
2. Measure the clearance A (4 locations: left, right, inside and

outside) between the track frame and the guide plate.
3. If the clearance A exceeds 4.0 mm (0.16 in), loosen bolt 0, and

pull out the shim to adjust the clearance at one end to 0.5 - 1.0
mm (0.02 - 0.04 in).
REMARK
Thickness of one shim is 1.0 mm (0.04 in).
3-33
24.1.9 ADJUSTING TENSION OF CENTER BRACE
(POWER TILT DOZER ONLY)
(POWER TILT, POWER PITCH DOZER ONLY)
When the blade assembly is removed for transportation, the

tension of the center brace must be adjusted when the blade is
assembled again. If the tension is not adjusted, the bushing at the
blade and straight frame mount will come out, and soil will enter.
This will result in damage or premature wear of the bushing.
Adjustment
blade control lever securely with the safety lever.
1. Adjust with shim @ so that the play of ball joint @ is 0.2 -

0.5 mm. t
Loosen bolt ,$i.
Install the blade assembly.
Operate the blade control lever to float the blade.
Insert a bar in hole (4j in the center brace, and turn it in the
direction of protrusion. When doing this, adjust so that clearance
D between the track and frame is the same on the left and right
sides.
Rotating torque: 26 - 49 Nm (Blade at FLOAT)
(2.5 - 5 kgm, 18 - 36 Ibft)
Standard distance MI between joints: 995 mm (39.2 in)
6. Tighten bolt (3).

Tightening torque: 441 + 49 Nm (45 + 5 kgm, 325 + 36 Ibft)
3-34
24.1.10 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;,open cover Qj, then remove FRESH
filter 3;.
2. Open inspection cover :.fi.iunder the front panel, pull up RECIRC

filter 5 , and remove it.
3. Clean filters ‘3.: and s,! with compressed air. If there is oil stuck
to the filter, or it is extremely dirty, wash it in a neutral agent.
After washing it, dry it completely before installing it again.
If the clogging of the filter cannot be removed by washing or
using compressed air, replace the filter with a new part.
3-35
24.1 .l1 CHECK, ADJUST All? CONDITIONER

Compressor pulley
15-18mm
(0.59 - 0.71 in)
CHECKINGTENSION OF COMPRESSORBELT
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. IO kg (22.05
@
lb)) and check that the tension is 15 - 18 mm (0.59 - 0.71 in). Drive pulley
AM088020
When the belt is new, there will be initial elongation, so always
adjust again after 2 or 3 days.
CHECK LEVEL OF REFRIGERANT (GAS)
I- A WARNING ‘_I
The refrigerant used in the cooler is colorless and odorless and
does not harm the atmosphere, but if the liquid gets into your
eyes or on your hands, it may cause loss of sight or frostbite,
so never loosen any part of the refrigerant circuit.
If the level of the refrigerant (gas) is low, the cooling effect will
be reduced. Run the engine at high 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.
l No bubbles in refrigerant flow: Correct
l Bubbles in refrigerant flow (bubbles continuously pass through):
Refrigerant level low
l 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.
24.1.12 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.
24.1.13 CHECK DOOR LOCK STRIKER

If the wear of the doors lock striker exceeds 0.5 mm (0.02 in),
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.
AD053300
3-36
24. 1.14 REPLACE DOOR DAMPER

Less than 2mm (0.08 in)
If the depth of the door damper rubber groove is less than 2 mm
(0.08 in), replace the damper.
There are two dampers each at the top and bottom on the left
and right doors.
24.1.15 CHECK WINDOW WASHER FLUID LEVEL, ADD

FLUID (MACHINES EQUIPPED WITH CAB)
If there is air in the window washer fluid, check the level and add
fluid.
Open the engine side cover on the right side, check the level of
the fluid in window washer tank Cl;, and if it is low, add automobile
window washer fluid.
When adding fluid, be careful not to let dirt or dust get in.
24.1.16 BLEED AIR FROM HEAD END OF RIGHT PITCH

CYLINDER
(POWER TILT, POWER PITCH DOZER ONLY)
Bleed the air if the work equipment has been removed or
repaired.
1. Raise the blade and run the engine at low idling.
2. Operate the left and right tilt 5 - 10 times to bleed the air from
the tilt circuit.
3. Operate the forward and rear pitch 5 - 10 times to bleed the air
from the bottom end of the right cylinder.
4. Set the left and right cylinders at the neutral position, then carry
out the following operations 5 - 10 times to bleed the air from
the head end of the right pitch cylinder.
,.I? Forward pitch
L
.,z’, Left tilt
.I?
,.ji: Right tilt
4, Rea’r pitch j
3-37
24.1.17 REPLACE WIPER BLADE

If the blade is damaged, it will not wipe the window clean, so
replace the blade.
Method of replacement
l Front, rear wiper
1. Remove screw 0, then remove the blade.
2. Install a new blade, then tighten screw @ securely.
l Door wiper
1. It is hooked at portion @I, so move the blade in the direction of
the arrow to remove it.
2. Install the new blade and hook it securely.
AM088090
3-38
24.1.18 CHECK IDLER OIL LEVEL, ADD OIL
A WARNING
When adding oil, if the machine is at an angle, be careful that
it does not turn over. Be careful also when getting on or off the
machine.
In particular, be sure to use the handrails and steps when
getting on or off the machine, and take other precautions to
ensure safety.
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.
Checking
1. Remove bolt \'!j,

then remove guide plate Q and shim 0.
REMARK
When removing shim @:,keep it in a safe place and be careful not
to lose it.
2. Loosen plug Q) and check if oil comes out.

If oil comes out the oil level is correct.
If no oil comes out, drive the machine on to a block to tilt the
machine. Then remove plug ?> and add engine oil through oil
filler port :F,.
AM086110
REMARK
If it is difficult to add oil, please contact your Komatsu distributor.
3. After adding oil, install plug 0.
4. Install guide plate Q) and shim @I with bolt 0.
REMARK
When installing guide plate 0, install the same number and
thickness of shim @ as was removed in Step 2.
For details of adjusting the shim thickness, see “24.1.8 ADJUST
IDLER CLEARANCE”.
3-39
24.2 CHECK BEFORE STARTING

24.2.1CHECK COOLANT LEVEL, ADD WATER
cooling water level, check the sub-tank when the engine is cold.
1. Open the engine side cover on the left side of the chassis, and
check that the cooling water is between the FULL and LOW
marks on sub-tank 0. If the water level is low, add water to the
FULL level through the water filler port in sub-tank 0.
REMARK
In summer, the coolant may overflow from the subtank 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.
AM066490
24.2.2CHECKING WITH MACHINE MONITOR Machines equippe with canopy

1. Turn starting switch @ 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
l If the lamps do not light up, there may be a failure or disconnec-
tion in the monitor, so please contact your Komatsu distributor. Machines equippe with cab
l When carrying out the checks before starting, do not relay only
on the monitor. Always carry out all the items listed for periodic
maintenance.
I_\
AM066510
OFF
ON
- START
AD052290
3-40
24.2.3 CHECK FUEL LEVEL, ADD FUEL

(MONITOR PANEL SPECIFICATION) G
-77 P
-----A WARNING -
Turn the engine starting switch to the ON position and check the
fuel level with fuel level gauge ;,G,Jon the monitor panel.
After checking, turn the switch back to the OFF position.
After completing work, fill the fuel tank through oil filler port @.
For details of the methad of opening and closing the cap, see
After adding fuel, tighten the cap securely.
Fuel capacity: 410 J?(108 US gal, 90 UK gal)
24.2.4 CHECK FUEL LEVEL, ADD FUEL

1. Removed the cap and check the fuel level using fuel gauge (Gj.
2. After completing work, fill the fuel tank through oil filler port (5).
Fuel capacity: 410 e (108 US gal, 90 UK gal)
3-41
24.2.5 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

1. Open the engine side cover on the left side of the chassis.
2. Remove dipstick @) and wipe the oil off with a cloth.
3. Insert dipstick @ fully in the oil filler pipe, then take it out again.
\c,,.
drain plug \:I:, 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
When checking the oil level after the engine has been operated,
ADO52340
wait for at least 15 minutes after stopping the engine before check-
ing.
24.2.6 CHECK OIL LEVEL IN POWER TRAIN CASE, ADD

OIL
1. Remove dipstick @, and wipe the oil off with a cloth.
2. Insert dipstick @$fully in the oil filler pipe, then take it out again.

,c$.
,F:.
drain plug F:, and check the oil level again.
AD052340
5. If the oil level is correct, tighten the oil filler cap securely.
REMARK
l When stopping the engine, check the oil level.
l When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.
3-42
24.2.7 CHECK BRAKE PEDAL TRAVEL

70-90 mm (2.8-3.5 in)
1. Depress the brake pedal all the way until it stops.
2. The distance of travel at the center of the pedal (position in the
diagram on the right) should be 70 - 90 mm (2.8 - 3.5 in).
3. When this value exceeds 90 mm (3.5 in), or the brake fails to
work, please contact your Komatsu distributor for adjustment.
0
a AM086570
24.2.8 CHECK DUST INDICATOR

Open the engine side cover on the left side of the chassis, and
check that the red piston has not appeared in the transparent
portion of dust indicator I .
If the red piston has appeared, clean or replace the element
immediately.
For details of the method of cleaning the element, see “24.1
WHEN REQUIRED”.
After checking, cleaning, and replacing, press the knob of dust
indicator I to return the red piston to its original position.
AD05209 1
24.2.9 CHECK THAT LAMPS LIGHT UP

Turn the head lamp switch, the rear lamp switch and the addi-
tional working lamp to the ON position and check that the head
lamps and rear lamps 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.
24.2.10 CHECK HORN SOUND
24.2.11 CHECK BACKUP ALARM SOUND
24.2.12 CHECK SEAT BELT FOR WEAR OR DAMAGE

Check the belt and mounting clamps, and if they are worn or
damaged, replace the seat belt.
24.2.13 CHECK FOR WATER AND SEDIMENT IN

WATER SEPARATOR, DRAIN WATER
The water separator separates water mixed in the fuel. If float @I
is at or above red line ‘J)), drain the water according to the following
procedure:
‘1. Loosen drain plug ,:.$Iand drain the accumulated water until the
float reaches the bottom.
2. Tighten drain plug 2:.
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 filter. See “24.5
AE082240
EVERY 500 HOURS SERVICE”.
3-43
24.3 EVERY 50 HOURS SERVICE
24.3.1 DRAIN WATER, SEDIMENT FROM FUEL TANK

Open the inspection cover at the bottom of the fuel tank, loosen
valve <g, and drain the fuel together with the water and sediment
accumulated at the bottom of the tank.
3-44

Maintenance for every 50 hours service should be carried out at
the same time.
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.
l Power tilt dozer
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 (I place)
5. Tilt brace ball joint (I place)
6. Brace ball joint (2 places)
7. Tilt brace thread (1 place)
3-45
l Power tilt - Power pitch dozer
AM088170
_ ___.___...-

4. Tilt cylinder ball joint (I place)
5. Pitch cylinder bail joint (1 place)
6. Brace ball joint (2 pkaCeS)
3-46
l Angledorer
AM088190

4. Tilt brace ball joint (2 places)
5. Tilt brace thread (2 places)
3-47
24.4.2 GREASE EQUALIZER BAR SIDE PIN
(LEFT AND RIGHT, 2 PLACES EACH:
TOTAL 4 PLACES)
1. Remove cover 0.
AM088200
2. Add grease to the grease fittings marked by the arrows.
REMARK
When adding grease, pump in three shots (pump the grease gun
lever three times) for each fitting, and check that grease is newly
discharged from the seal lip.
If no grease is newly discharged from the seal lip, continue to pump
in grease until grease is discharged.
3. Install the cover.
24.4.3 GREASE EQUALIZER BAR CENTER PIN (1 place)
1. Open the left side cover.
2. Add greace to the grease fittings marked by the arrows.
3-48
24.4.4 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
The oil is at high temperature immediately after the machine
1. Stop the machine so that drain plug @ is directly at the bottom.
2. Remove oil level plug ;& and check whether the final drive case
is filled with oil to lower edge of the plug hole.
3. If the oil level is still too low, add engine oil through the plug hole
until the oil overflows.
24.4.5 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
When removing the oil filler cap, oil may spurt out, so stop the
the cap slowly to release the internal pressure before removing
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.
Ii
ED
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 0 Properrange
H and L in sight gauge !@.
L
2. If the level is below the L mark, add engine oil through oil filler
I AC053410
wait for the hydraulic oil to cool down, then drain the excess oil
1 from the drain plug.
3-49
24.4.6 CHECK LEVEL OF BATTERY ELECTROLYTE

Carry out this check before operating the machine.
7 g WARNING
l To avoid gas explosions, do not bring fire or sparks near the
battery.
l Battery electrolyte is dangerous. If it gets in your eyes or on
your skin, wash it off with large amounts of water, and
consult a doctor.
1. Open the battery cover.
2. Remove cap t f, and check that the electrolyte is at the specified

level (10 to 12 mm (0.39 to 0.47 in) above the plate). If the
electrolyte level is low, add distilled water to the specified level.
If the battery electrolyte is spilled, have dilute sulphuric acid
added.
3. When adding distilled water to any cell at cap .I’, add distilled
water also to the other cells.
4. Clean the air hole in the battery cap, then tighten the cap
securely.
NOTICE
When adding distilled water in cold weather, add it before
starting operations in the morning to prevent the electrolyte from
freezing.
3-50
24.4.7 CHECK FAN BELT TENSION, ADJUST

Checking
The belt should normally deflect by 6 - 10 mm (0.24 - 0.39 in)
when pressed with the finger (with a force of approx. 6 kg) at a point
midway between the alternator pulley and fan pulley.
AM088270
Adjusting
1. Loosen bolts and nuts (I), Q and 0.
2. Turn nut (3) clockwise, then move alternator @to adjust the belt
tension so that the deflection is 6 - 10 mm (0.24 - 0.39 in) when
pushed with a force of 6 kg.
3. Tighten the bolts and nuts 0J, 0 and @ to fix alternator @ in

position.
4. 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.
5. If any belt has stretched and there is no allowance for adjust-

ment, or if there are cuts or cracks on any belt, replace both belts
at the same time.
6. When the new belt is set, readjust it after operation for an hour.
3-51
24.4.8 DRAIN WATER AND SEDIMENT FROM FUEL

FILTER
1. Open the engine side cover on the left side, loosen drain plug @
at the bottom of the filter, and drain the fuel together with the
water and sediment accumulated at the bottom of the tank.
2. Tighten drain plug 0.
3. Loosen the knob of feed pump @ and operate it 50 - 60 times

up and down. This will bleed the air.
4. Push in the knob of feed pump (2) and tighten it.
24.4.9 CHECK, CLEAN ADDITIONAL FUEL STRAINER

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. Set the strainer in the case, then tighten the cap.
4. After installing, open the fuel supply valve,
3-52
24.4.10 REPLACE POWER TRAIN OIL FILTER ELEMENT

1. Rernove top mounting bolts (2) of filter cover 0, then use the
bottom hinge as the fulcrum to open the cover to the outside.
2. Remove seal 13.;installed to the frame.
When installing When removing

AM088320
3. Remove mounting bolts @ of filter 0, then remove cover 0.
4. Remove the grommet under the fender, loosen drain plug @,

and drain the oil inside the filter case.
5. Take out element 0.
6. Clean the removed parts and the inside of the case, then install
a new element.
Set so that the side hole of cover @ is in the direction to match
hole ,.n) of filter case 0, then tighten with bolts @.
7. Install drain plug @.
6. After installing, loosen air bleed plug ‘<&I,start the engine, and
when oil spurts out, tighten the plug.
AM088330
9. Close filter cover 0, and tighten bolts Qj.
10. Install frame seal 0.
NOTICE
When installing seal &I, always close filter cover @ first.
If the filter cover is closed after the seal is installed, the seal will
be damaged.
Filte; cover
AM088350
24.4.11 CHECK BRAKE PERFORMANCE
a 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.
1. Start the engine.
2. Set safety lever ,.!, to the FREE position then operate blade
control lever 2 to raise the blade.
Leave the safety lever to the FREE position.
3. Set parking lever .J,; to the FREE position.
4. Depress brake pedal !& and move joystick (3 in 2nd.
5. Operate fuel control lever $I) to raise the engine speed gradually
to full throttle.
6. Check that the machine does not move. This indicates that brake
performance is normal. Machines equip
3-54

Maintenance for every 50 and 250 hours service should be
carried out at the same time.
24.5.1 REPLACE FUEL FILTER CARTRIDGE
l 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 cartridge.
2. Using a filter wrench, turn filter cartridge 0 counterclockwise 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 l/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 filter
cartridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.
5. Loosen the knob of feed pump @ and operate it 50 - 60 times

up and down. This will bleed the air.
6. Push in the knob of feed pump (& 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
damage 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.
3-55
l Method of using automatic air bleed mechanism.
g WARNING
When cranking the engine, confirm the safety around the en-
gine, as the engine may start.
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 control
lever is at the low idling position.
2. Place the parking 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.
NOTICE
When the engine has run out of fuel, carry out the same
procedure and crank the engine for 15 - 20 seconds.
Repeat this operation 2 - 3 times to bleed the air.
Do not rotate the starting motor continuously for more than 20
seconds. Wait for 1 - 2 minutes before rotating again.
The time taken to bleed the air is shorter when the fuel tank is full.
3-56
24.5.2 CHANGE OIL IN ENGINE OIL PAN, REPLACE

ENGINE OIL FILTER CARTRIDGE
The oil is at high temperature after the engine has been oper-
tions. Wait for the oil to cool down before changing it.
A CAUTION
When draining the oil, do not remove drain plug @.
Prepare the following.

l Container to catch drained oil: Min 38 !Zcapacity
l Refill capacity: 38 e (10.03 US gal, 8.36 UK gal)
l Socket wrench, filter wrench.
1. Remove the cover at the bottom of the machine and set a

container to catch the oil under the drain plug.
2. Loosen drain plug @ (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 Komatsu distributor.
4. Install drain plug (ep,!.
5. Using a filter wrench, turn filter cartridge (1>counterclockwise to

remove it. When doing this, to prevent getting oil on yourself, do
not carry out this operation from immediately under the car-
tridge.
In particular, if this operation is carried out immediately after
stopping the engine, a large amount of oil will come out, so wait
for 10 minutes before starting the operation.
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 - 1 turn.
8. After replacing the filter cartridge, add engine oil through oil
filler :FJ until the oil level is between the H and L marks on the
dipstick.
3-57
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 “24.2 CHECK BEFORE STARTING”.
NOTICE
Even if the machine has not been operated for 500 hours, the oil
and filter cartridge must be replaced when the machine has been
operated for 6 months.
In the same way, even if the machine has not been operated for
6 months, the oil and filter cartridge must be replaced when the
machine has been operated for 500 hours.
3-58
Maintenance for every 50,250 and 500 hours should be carried

out at the same time.
24.6.1 CHANGE OIL IN POWER TRAIN CASE, CLEAN

STRAINERS (POWER TRAIN STRAINER,
SCAVENGING PUMP STRAINER)
g WARNING
l The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before
starting the operation.
l The undercover is heavy.
Never try to open or close the cover when directly beneath
it. When removing bolts 0, carry out the work from the rear
below the cover so that you can easily get out of the way.

0 Container to catch drained oil: Min 50 e capacity
1. Loosen drain plug @(with a slit), drain the oil, then tighten drain
plug 8 again.
Do not remove drain plug @.
2. Remove the undercover at the bottom rear of the machine as

follows.
(1) Remove 2 bolts @ at the front of the machine.
(2) Support the cover with your elbow while gradually removing
2 bolts @ at the rear of the machine.
(3) Lower the cover gradually to open it.
3. Loosen mounting bolt @ of the power train strainer, then re-

_..\
mOVe COVer @J.
4. Take out spring 0, then take out strainer 8.
5. Remove all dirt from strainer 0, then wash in clean diesel oil or c, ”
%*
flushing oil. + Frontpf *+
machme *
Clean the case interior and the removed parts. 0
*
*
s,* &I
GL
+
Dangerous place
AM088450
3-59
6. Loosen mounting bolt @I of the scavenging pump strainer, then

remove cover @.
7. Take out spring 0, then take out strainer @J.
8. Remove all dirt from strainer @I, then wash in clean diesel 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 “24.4 EVERY 250 HOURS SERVICE”.
11. Refill the specified quantity of engine oil through oil filler @.
12. Check that the oil is at the specified level.

For details, see “24.2 CHECK BEFORE STARTING”.
If the spring or strainer are damaged, replace them.
3-60
24.6.2 CHANGE OIL IN FINAL DRIVE CASE
t g 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.

0 Container to catch drained oil: Min. 27 e capacity .
0 Refill capacity:
D65E: (each) 24 .Q(6.34 US gal, 5.28 UK gal)
D65P: (each) 27 k?(7.13 US gal, 5.94 UK gal)
1. Stop the machine so that drain plug @ is directly at the bottom.
2. Remove oil level plug @ and oil filler plug 0, then remove drain
plugs ,:3) and (3, and drain the oil. After draining the oil, tighten
the plugs.
3. Add engine oil to the specified level through the hole in oil filler
plug ,.0.
4. Check that the oil is at the specified level.

For details, see “24.4 EVERY 250 HOURS SERVICE”‘.
3-61
24.6.3 CLEAN BREATHER
Remove the breather and wash out dust remaining inside with
diesel oil and flushing oil.
1. Power train (transmission) case breather (1 place)

Remove the inspection cover at the rear of the operator’s seat.
Breather @ is installed to the left side of the window (right side
of chassis).
AM088500
24.6.4 GREASE UNIVERSAL JOINT

Apply grease to the grease fittings (2 places) shown by arrows.
Never try to open or close the cover when directly beneath it

When removing bolts 0, carry out the work from the rear below
the cover so that you can easily get out of the way.
Remove the undercover at the rear bottom of the chassis as

follows.
(1) Remove 2 bolts @ at the front of the machine.

(2) Support the cover with your elbow while gradually removing 2
bolts @ at the rear of the machine.
(3) Lower the cover gradually to open it.
3-62
24.6.5 REPLACE CORROSION RESISTOR CARTRIDGE

(D65P ONLY 1
1. Screw in valve I at the top of the corrosion resistor.
2. Using a filter wrench, turn cartridge /?, to the left, and remove
it.
s. Coat the seal surface of the new cartridge with engine oil, then
install it to the filter holder.
4. When installing, bring the packing surface into contact with the
seal surface of the filter holder, then tighten approx. 2/3 turns.
5. Open valve 1
Always use a genuine Komatsu cartridge.
24.6.6 CHECK ALL TIGHTENING PARTS OF

TURBOCHARGER (D65P ONLY)
Contact your Komatsu distributor to have the tightening portions
checked.
24.6.7 CHECK PLAY OF TURBOCHARGER ROTOR

(D65P ONLY)
Contact your Komatsu distributor to have the play checked.
24.6.8 CHECK FOR LOOSE ROPS MOUNT BOLTS

Check for loose and damaged bolts. If any loose bolt is found,
tighten to a torque of 927 5 103 Nm (94.5 r 10.5 kgm, 664 f 76 Ibft)
If any damaged bolt is found, replace the bolt with a genuine
Komatsu bolt.
3-63
Maintenance for every 50, 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
Ah WARNING
The oil is at high temperature immediately after the machine has
been operated. Wait for the oil to cool down before changing the
oil. When removing the oil filler cap, turn it slowly to release the
internal pressure, then remove it carefully.

0 Container to catch drained oil: Min. 55 e capacity
1. Lower the blade on the ground securely, stop the engine and
slowly turn the cap of oil filler IF) to release the internal pressure.
Then, remove the cap.
2. Remove the cover at the bottom of the hydraulic tank.
3. Remove cap :!_I,loosen drain valve @,Ito drain the oil, then tighten
valve (2, again. After tightening, install the cover.
When loosening drain valve 8, be careful not to get the oil on
you.
4. Remove the grommet under the fender, loosen drain plug 0, and
drain the oil.
5. Remove top mounting bolts (2, of filter cover @, then use the
bottom hinge as the fulcrum to open the cover to the outside.
6. Remove seal ‘6; installed to the frame.
When installing When removing

AM088560
3-64
7. Remove mounting bolt @ of filter 0, then remove cover 0.
8. Take out element @I.
9. Clean the removed parts and the inside of the case, then install
a new element.
Always use a genuine Komatsu element.
10. Install drain plug 0.
11. After installing, loosen air bleed plug 0, start the engine, and
when oil spurts out, tighten the plug.
12. Close filter cover 0, and tighten bolt 0.
13. Install frame seal @.

AM088570
NOTICE
When installing seal @, always close filter cover @ first.
If the filter cover is closed after the seal is installed, the seal will
be damaged.
14. Add the specified amount of engine oil through the oil filler 0.
AND LIJBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
15. Check that the oil is at the specified level. For details, see “24.4
EVERY 250 HOURS SERVICE”. I
\
Filter cover
AM088350
3-65
24.7.2 CLEAN, CHECK TURBOCHARGER

(D65P ONLY)
Contact your Komatsu distributor for cleaning or inspection.
24.7.3 CLEAN ENGINE BREATHER ELEMENT

Wipe off all the dirt around the breather on the cam follower
cover.
Remove the breather.
Wash the whole breather in diesel oil or flushing oil, then blow
it dry with compressed air.
Replace the breather O-ring with a new part, coat with engine oil,
and install it.
24.7.4 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 dis-
tributor to have the parts replaced.
24.7.5 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.
24.7.6 CHECK ENGINE VALVE CLEARANCE, ADJUST

Contact your Komatsu distributor for inspection or adjustment.
3-66
Maintenance for every 50,250,500,1000 and 2000 hours service

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

Check that there is oil leakage, water leakage, or clogging of the
drain hole. If any abnormality is found, contact your Komatsu
distributor for disassembly and repair or replacement.
3-67
MEMO
SPECIFICATIONS
4-l
25. SPECIFICATIONS
D65E-12 D65P-12
OPERATING WEIGHT (without operator)
18310 kg 20180 kg
With tilt dozer and ROPS cab
(40374 lb) (44497 lb)
PERFORMANCE
l Travel speed Forward 1st 3.9 km/h (2.4 MPH)

_---.-~_-
2nd 6.8 km/h (4.2 MPH)
--.-- --_--
3rd 10.6 km/h (6.6 MPH)
Reverse 1st 5.0 km/h (3.1 MPH)

_~--___-
2nd 8.6 km/h (5.3 MPH)
3rd 13.4 km/h (8.3 MPH)

_-.- --~-
l Maximum drawbac pull 22820 kg (50318 lb)
SOUND LEVEL
”
l Surrounding (Sound power level L WA) 108 dB !A)

l Operator’s (sound pressure level L PA)
measurement procedure described in 82 dB (A)
IS0 6394 or 86/622/ECC
ENGINE
Komatsu 6D125-1 Komatsu S6D125E-1

o Model
diesel engine diesel engine
_.._____
l Flywheel horsepower 177 HP 187 HP
--
799 Nm (81.5 kgm)/ 981 Nm (100 kgm)/
l Max. torque
1100 rpm 1200 rpm
0 Startina motor 24 V 7.5 kW
l Alternator 24 V 35 A
l Battery 12 V 140 Ah x 2 pieces
4-2
25. SPECIFICATIONS
D65E-12
l Machines equipped with tiltdozer
The values without ( 1 are the values when the tiltdozer or semi-U blade are installed.
The values with ( ) are the values only when the semi-U blade is installed.
Overall length 5260 l17’3”l

(5750) 118’10”1
AM080600
l Machines equipped with angledozer

25. SPECIFICATIONS
l With cab + ROPS canopy
AM088620
l With canopy
AM088630
l With ROPS canopy
4-4
25. SPECIFICATIONS
D65P-12
l Machines equipped with tiltdozer
L Overall width 3970 l13’1

J
AM066650
l Machines equipped with power tilt, power pitch dozer
---_._ ----..
/sa
AM068660
4-5
With cab + ROPS canopy
,-
AM066670
l With canopy
l With ROPS canopy
AM086690
4-6
OPTIONS, ATTACHMENTS -
5-1
.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.
If you do not contact Komatsu, we cannot accept any responsibility for any accident or failure.
a WARNING
Precautions for removal and installation operations
When removing or installing attachments, obey the following precautions and take care to ensure
safety during the operation.
Carry out the removal and installation operations on a flat, firm ground surface.
When the operation is carried out by two or more workers, determine signals and follow these
during the operation.
When carrying heavy objects (morethan 25 kg (55 lb)), use a crane.
When removing heavy parts, always support the part before removing it.
When lifting such heavy parts with a crane, always pay careful attention to the position of the
center of gravity.
It is dangerous to carry out operations with the load kept suspended. Always set the load on a
stand, and check that it is safe.
When removing or installing attachments, make sure that they are in a stable condition and will
not fall over.
Never go under a load suspended from a crane.

Always stand in a position that is safe even if the load should fall.
NOTICE
Qualifications are required to operate a crane. Never allow the crane to be operated by an
unqualified person.
For details of the removal and installation operations, please contact your Komatsu distributor.
5-2
27. USING SEAT BELT
When operating a machine equipped with ROPS, be sure to use ‘.

the seat belt.
A WARNING
l Before fastening the seat belt, inspect the securing brackets
and belt for abnormal conditions.
Replace any worn or damaged seat belt or the securing
brakets.
l Adjust and fasten the seat belt before operating the machine.
l Always use seat belt when operating the machine.
l Do not use seat belt with either half of the belt kinked.
27.1 FASTEN THE BELT AND REMOVE

FOLLOWING MANNER
IT IN THE
Adjust the seat so that the brake pedal can be depressed all the
1
way with the operator’s back against the backrest.
After positioning the seat, adjust the tether belt 0. With the seat
unoccupied, tense the belt slightly across the seat and install.
AM088700
Sit in the seat. Hold buckle 83 with your left hand and tonque 0
with your right hand, put the tongue into the buckle. Check that
the belt has locked by pulling it.
When removing the belt, raise the tip of the buckle lever to
release it.
Fasten belt along your body without kinking it. Adjust the lengths
of the belt on both the buckle and the tongue sides so that the
buckle is located at the mid-point of your body front.
5-3
27.2 ADJUST THE BELT LENGTH IN THE
FOLLOWING MANNER
27.2.1 TO SHORTEN THE BELT

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

Pull the belt while holding it at a right angle to buckle or tongue.
Inspect bolts and fittings on the chassis for tightness. Retighten

any loose bolts to 25 + 5 Nm (2.5 f 0.5 kgm, 18 f 3.6 Ibft) torque.
If the seat is scratched or frayed or if any of the fittings are

broken or deformed from long service, replace the seat belt
immediately.
I AM088720
5-4
28. HANDLING DELUXE SEAT
A WARNING
l Adjust the seat position at the beginning of each shift or
when opertors change.
l Adjust the seat so that the brake pedal can be depressed all
the way with the operator’s back against the backrest.
Fore-aft adjustment of seat

Move lever ;!J to the right set the seat to a position where it is
easy to operate, then release the lever.
Fore-aft adjustment: 160 mm (6.3 in) (9 stages)
Weight adjustment of seat

Turn knob \?, under the seat to match the weight adjustment
scale with your own weight.
The weight can be adjusted within a range of 50 - 120 kg (110
- 265 lb)
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 Adjusting 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 Adjusting seat tilt

Pull up lever 4, to remove the lock, set the seat to the desired
position, then release the lever to lock the seat in position.
Tilt adjustment: 13+ up and down.
5-5
28. HANDLING DELUXE SEAT
(Q Height adjustment of seat

Pull levers @ and @ up at the same time to remove the lock, set
the seat to the desired position, then release the lever to lock the
seat in position.
Height adjustment: 65 mm (2.6 in)
(Fj Adjusting direction of seat

When lever $ is moved to the left, it is possible to turn the seat
manually to the right to change the position by 15’.
After changing the direction of the seat, move the lever back
securely and lock it.
Adjusting height of headrest _

To make it higher
Hold the headrest and pull it up.
AM088740
To make it lower
Keep knob (7) pushed down, and push the headrest down to the
desired position.
Height adjustment: 60 mm (2.6 in) (2 stages) I c-3 I
T\
1 AM088750
5-6
29. HANDLING ACCUMULATOR
A WARNING
On machines equipped with an accumulator, for a short time
after the engine is stopped, if the blade control lever is moved
to the LOWER position, the work equipment will move down
After stopping the engine, always place the safety 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 of the accumulator, it is necessary to release
the gas from the accumulator, so please contact your Komatsu
distributor.
The accmulator 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.
Therefore, if the control lever is moved in the direction to lower the
work equipment, it is possible for the work equipment to move
The accumulator is installed to the position shown in the diagram
on the right.
29.1 METHOD OF RELEASING PRESSURE IN

OPERATING CIRCUIT ON MACHINE EQUIPPED
WITH ACCUMULATOR
1. Lower the work equipment and stop the engine.
2. After stopping the engine, operate the control lever fully to the
front, rear, left, and right to release the pressure inside the work
equipment circuit.
However, the pressure cannot be completely removed, so when
removing the work equipment circuit, loosen the screw slowly,
and never stand in the direction where the oil spurts out.
5-7
30. EQUIPPING THE FIRE EXTINGUISHER AND THE
FIRST-AID KIT
E(lklip the fire extinguisher and the first-aid kit at the ill&trated
position, if applicable.
___.._._._______..Y ^--._- _.. -
First-aid kit
Fire extyguisher
AN140280
5-8
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696
SEAM007102
BULLDOZER
SERIAL NUMBERS
D65E-60948 and up
D65P-60891
WARNING
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintain-
ing 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
1995 Komatsu has Operation & Maintenance Manuals written in
All Right Reserved some other languages. If a foreign language manual is
Printed in USA 02-95 necessary, contact your local distributor for availability.
DATAKOM

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SEAM0071 02

August 1998 Copyright 1998 Komatsu America International Company

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

3.1 INTENDED USE

EASY MAINTENANCE AND HIGH DURABILITY

3.3 BREAKING IN THE MACHINE

4.1 MACHINE SERIAL NO. PLATE POSITION

This IS at the front bottom right of the operator’s seat.

4.2 ENGINE SERIAL NO. PLATE POSITION

4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Service personnel for your machine:

_-.--_..-_-- _- ____ _ _-___

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

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

7. Precautions during operation .......................................................................................................... I- 9

8. Precautions for maintenance ........................................................................................................... 1-17

9. Position for attaching safety labels ................................................................................................ l-24

11. Explanation of components ............................................................................................................. 2- 6

13. Transportation .. .. . .. .. . .. .. . . .. .. .. .. .. .. . . .. .. . .. .. . . .. ... . . .. .. . .. . .. . .. . ... . .. .. .. .. .. .. .. . . .. .. .. .. ... . .. .. .. . .. .. . . .. .. . .. . ... . . ........... 2-79

14. Cold weather operation .................................................................................................................... 2-85

15. Long-term storage ............................................................................................................................. 2-88

16. Troubleshooting . ... .. .. .. . . .. .. . .. . .. .. . ... . .. . .. ... . .. . .. .. . .. .. . . .. .. .. . . .. .. . .. ... .. .. .. . . .. .. . .. . .. .. . .. . .. .. .. .. .. .. .. ... . . .. . .. . .......... 2-89

17. Guides to maintenance . . .. . .. .. . . . .. .. .. .. . . .. . ... .. . .. . . .. . . .. .. . .. .. .. .. .. .. . .. .. .. . .. . .. . . .. . .. . .. . .. . .. .. . ... .. . . . .. .. . . .. .. .. .. .. . . .. . 3- 2

18. Outlines of service . . . .. . .. . . .. . .. . . .. . .. . . . ... .. . .. . .. . . .. . .. .. . . .. .. . . . .. .. . . . .. .. . .. . . .. .. . . .. .. . . .. .. . . . . ... . . .. .. . .. .. .. . .. . . .. .. . .. . . .. . . 3- 5

19. Wear parts list . .. . . .. .. . .. .. . .. .. .. . .. . . . .. .. . . . .. .. . . .. .. . . . .. .. . . .. . .. . . . .. . ... . .. .. .. . . .. . .. . . .. .. . . .. .. . .. .. .. . .. . .. . .. . .. . .. . . .. . .. .. . . .. .. . 3- 8

23. Maintenance schedule chart . .. . .. .. .. . .. . . . .. . .. . . .. .. . .. .. .. . . .. . .. . .. . . .. .. . . . . ... . . .. .. . . . ... . . .. ... . . .. . . .. . .. . . . ... . . .. . . .. . .. .. .. 3-18

24. Service Procedure .. . . . .. .. . . . . .. . .. . . .. . .. . .. . . .. . . . .. .. . . . .. .. . . .. .. .. . .. . .. . . . ... . .. . .. ... . .. .. .. . . .. .. .. . .. . .. . .. . .. .. .. ... .. . .. .. .. . . . ... . . 3-21

25. Specifications . . .. .. .. . . . . .. .. .. . . .. .. .. .. .. . .. . . . ... . ... . .. .. . .. . .. .. .. . .. .. . .. .. . . . . ... . . .. . .. .. . .. . . .. .. . .. . . .. . .. . . . .. .. . . . .. .. .. .. .. .. . . . .. .. . 4- 2

26. General precautions ........................................................................................................................... 5- 2

27. Using seat belt ......................................................................................... .:. ...................................... 5- 3

28. Handling deluxe seat ......................................................................................................................... 5- 5

29. Handling accumulator ....................................................................................................................... 5- 7

This safety section also contains precautions for optional equip-

CLOTHING AND PERSONAL PROTECTIVE ITEMS

1 MOUNTING AND DISMOUNTING 1

FIRE PREVENTION FOR FUEL AND OIL 1

A0055020 AM)55030 A0055040

l To prevent hot water from spurting out:

l To prevent hot oil from spurting out:

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

FIRE EXTINGUISHER AND FIRST AID KIT

Know where a first aid kit is located.

Know what to do in the event of a fire.

Equipping the fire extinguisher and the first-aid kit

Do not operate machine with ROPS removed if equipped.

PRECAUTIONS FOR AlTACHMENTS 1

--/ MACHINES WITH ACCUMULATOR 1

7.1 BEFORE STARTING ENGINE

If you need to operate on a street, protect pedestrians and cars

If water lines, gas lines, and high-voltage electrical lines may be

Check the depth and flow of water before operating in water or

Be sure a fire extinguisher is present and working.

1 PRECAUTIONS FOR MIRRORS, WINDOWS AND UGHTS 1

4 PRECAUTIONS FOR SLIDING GLASS INTERMEDIATE LOCK 1

7.2 OPERATING MACHINE

When starting the engine, sound the horn as an alert.

Start and operate the machine only while seated.

Check that the backup alarm is working properly.

Do not add grease or oil after starting the engine.