SEAM057800T

Operation & Maintenance

Manual

D21A-8
D21P-8
BULLDOZER
SERIAL NUMBERS D21A-8 83001 and up
D21P-8 83001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp..

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 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2003 Komatsu

Printed in U.S.A.
Komatsu America Corp.
October 2003
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FOREWORD FOREWORD

FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.

WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.

Read this manual thoroughly and understand its contents fully.

Read the safety messages and safety labels given in this manual carefully so that they should be understood fully.

Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved
in working on the machine can consult it periodically.

In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.

When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.

In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in
the past are also displayed in { }.

Storage location for the Operation and Maintenance Manual:

Pocket at rear of operator's seat

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FOREWORD FOREWORD

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FOREWORD FOREWORD

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FOREWORD SAFETY INFORMATION

SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.

Signal words

The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.

Example of safety message using signal word

WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.

Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.

This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.

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

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SAFETY INFORMATION FOREWORD

Safety labels

Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.

Example of safety label using words

Safety labels using pictogram

Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous
condition is displayed inside a triangle and the method of avoiding
the hazardous condition is shown inside a circle.

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, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.

The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.

The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))

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FOREWORD INTRODUCTION

INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Dozing
Smoothing
Cutting into hard or frozen ground or ditching
See the section "WORK POSSIBLE USING BULLDOZER (PAGE 3-49)" for further details.

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE

(A) Front (E) Operator's seat

(B) Rear (F) Sprocket
(C) Left
(D) Right

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

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NECESSARY INFORMATION FOREWORD

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

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

On the inside of the L.H. armrest.
The design of the nameplate differs according to the territory.

ENGINE SERIAL NO. PLATE

On the upper side of the engine cylinder head cover.

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FOREWORD NECESSARY INFORMATION

EMISSION CONTROL INFORMATION LABEL

On the upper side of the engine cylinder head cover.

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

POSITION OF SERVICE METER

This is at the top of the front panel.

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NECESSARY INFORMATION FOREWORD

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.

Engine serial No.

Product identification number (PIN)

Distributor name

Address

Service Personnel

Phone/Fax

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FOREWORD CONTENTS

CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 7
NECESSARY INFORMATION 1- 8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 8
ENGINE SERIAL NO. PLATE 1- 8
EMISSION CONTROL INFORMATION LABEL 1- 9
POSITION OF SERVICE METER 1- 9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 10
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 4
POSITIONS OF SAFETY PICTOGRAMS 2- 4
SAFETY LABELS 2- 5
GENERAL PRECAUTIONS 2- 8
PRECAUTIONS FOR OPERATION 2- 16
STARTING ENGINE 2- 16
OPERATION 2- 18
TRANSPORTATION 2- 22
BATTERY 2- 23
TOWING 2- 25
PRECAUTIONS FOR MAINTENANCE 2- 26
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 4
FRONT PANEL 3- 4
SWITCHES 3- 10
CONTROL LEVERS AND PEDALS 3- 12
FUSE 3- 18
DOOR POCKET 3- 18
OPERATION 3- 19
CHECK BEFORE STARTING ENGINE, ADJUST 3- 19
STARTING ENGINE 3- 32
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3- 35
STOPPING ENGINE 3- 37
MACHINE OPERATION 3- 38
SHIFTING GEAR 3- 42
SHIFTING BETWEEN FORWARD AND REVERSE 3- 43
STEERING MACHINE 3- 44
PRECAUTIONS FOR OPERATION 3- 48
WORK POSSIBLE USING BULLDOZER 3- 49
PARKING MACHINE 3- 51
CHECK AFTER FINISHING WORK 3- 53
LOCKING 3- 53
TIPS FOR LONGER UNDERCARRIAGE LIFE 3- 54

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CONTENTS FOREWORD

HANDLING RUBBER SHOES (RUBBER SHOES ONLY) 3- 57

TRANSPORTATION 3- 62
TRANSPORTATION MEANS 3- 62
LOADING, UNLOADING WORK 3- 62
LIFTING MACHINE 3- 65
COLD WEATHER OPERATION 3- 66
PRECAUTIONS FOR LOW TEMPERATURE 3- 66
AFTER COMPLETION OF WORK 3- 68
AFTER COLD WEATHER 3- 68
LONG-TERM STORAGE 3- 69
BEFORE STORAGE 3- 69
DURING STORAGE 3- 69
AFTER STORAGE 3- 69
TROUBLESHOOTING 3- 70
AFTER RUNNING OUT OF FUEL 3- 70
MACHINE TOWING METHOD 3- 70
IF BATTERY IS DISCHARGED 3- 71
OTHER TROUBLE 3- 75
MAINTENANCE 4- 1
GUIDE TO MAINTENANCE 4- 2
OUTLINE OF SERVICE 4- 4
OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
RELATING TO ELECTRIC SYSTEM 4- 6
WEAR PARTS LIST 4- 7
WEAR PARTS LIST 4- 7
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 8
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 4- 8
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12
TORQUE LIST 4- 12
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 13
SAFETY CRITICAL PARTS 4- 13
MAINTENANCE SCHEDULE CHART 4- 14
MAINTENANCE SCHEDULE CHART 4- 14
SERVICE PROCEDURE 4- 16
INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS) 4- 16
WHEN REQUIRED 4- 17
CHECK BEFORE STARTING 4- 38
EVERY 50 HOURS SERVICE 4- 39
EVERY 250 HOURS SERVICE 4- 40
EVERY 500 HOURS SERVICE 4- 46
EVERY 1000 HOURS SERVICE 4- 50
EVERY 2000 HOURS SERVICE 4- 55
EVERY 4000 HOURS SERVICE 4- 56
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAUTIONS 6- 2
PRECAUTIONS RELATED TO SAFETY 6- 2
DECELERATOR PEDAL 6- 3
SUSPENSION SEAT 6- 4

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FOREWORD CONTENTS

ADJUSTMENT 6- 4
SEAT BELT 6- 4
INDEX 7- 1

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SAFETY SAFETY

SAFETY
SAFETY LABELS 2- 4
POSITION OF SAFETY PICTOGRAMS 2- 4
SAFETY LABELS 2- 5

GENERAL PRECAUTIONS
Safety rules 2- 8
If abnormalities are found 2- 8
Clothing and personal protective items 2- 8
Fire extinguisher and first aid kit 2- 8
Safety features 2- 8
Keep machine clean 2- 9
Inside operator's compertment 2- 9
Always apply lock when leaving operator's seat 2- 9
Handrails and steps 2- 10
Mounting and dismounting 2- 11
No people on attachment 2- 11
Crushing or cutting prevention 2- 11
Prevention of burns 2- 11
Fire prevention 2- 12
Action if fire occurs 2- 13
Window washer liquid 2- 13
Precautions when using ROPS (Roll Over Protective Structure) 2- 13
Precautions for attachments 2- 13
Unauthorized modification 2- 13
Safety at worksite 2- 14
Working on loose ground 2- 14
Do not go close to high-voltage cables 2- 14
Ensure good visibility 2- 15
Ventilation for enclosed aresa 2- 15
Checking signalman's signals and signs 2- 15
Emergency exit from operator's cab 2- 15
Be careful about asbestos dust 2- 15

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SAFETY SAFETY

PRECAUTIONS FOR OPERATIONS 2- 16

BEFORE STARTING ENGINE 2- 16
Checks before starting engine 2- 16
Precautions when starting 2- 16
Precautions in cold areas 2- 17
AFTER STARTING ENGINE 2- 18
Checks after starting engine 2- 18
Precautions for moving machine forward or in reverse 2- 18
Precautions when traveling 2- 18
Traveling on slopes 2- 19
Using brake 2- 19
Operate carefully on snow 2- 19
Parking machine 2- 20
TRANSPORTATION 2- 22
Loading and unloading 2- 22
Shipping 2- 22
BATTERY 2- 23
Battery hazard prevention 2- 23
Starting with booster cable 2- 24
TOWING 2- 25
When towing 2- 25

PRECAUTIONS FOR MAINTENANCE 2- 26

Warning tag 2- 26
Keep work place clean and tidy 2- 26
Appoint leader when working with others 2- 26
Stop engine before carrying out inspection and maintenance 2- 27
Two workers for maintenance when engine is running 2- 28
Proper tools 2- 29
Personnel 2- 29
Attachments 2- 29
Precautions for work under machine and work equipment 2- 29
Noise 2- 29
Precautions when using hammer 2- 30
Repair welding 2- 30
Removing battery terminal 2- 30
Precautions when Using high-pressure grease to adjust track tension 2- 30
Do not disassemble recoil spring 2- 30
Precaution with high-pressure oil 2- 31
Handling high-pressure hoses 2- 31
Waste material 2- 31
Maintenance for air conditioner 2- 31
Compressed air 2- 32
Periodic replacement of safety critical parts 2- 32

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SAFETY LABELS SAFETY

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

POSITIONS OF SAFETY PICTOGRAMS

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SAFETY SAFETY LABELS

SAFETY LABELS
(1) Precautions for operation, inspection and maintenance
(09651-03001)

(2) Precautions when traveling in reverse

(09802-13000)

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

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SAFETY LABELS SAFETY

(4) Precautions for high-temperature cooling water (09668-03001)

(5) Precautions for high temperature oil (09653-03001)

(6) Caution for adjusting track tension (09657-03003)

(7) Caution for battery cable (09808-03000)

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SAFETY SAFETY LABELS

(8) Caution for battery (09664-30083)

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

(10) Caution for approach when machine moving (09812-13000)

(11) Caution for ROPS (09620-A2000)

(12) Prohibition of jump start (09842-A0481)

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GENERAL PRECAUTIONS SAFETY

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

IF ABNORMALITIES ARE FOUND

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

CLOTHING AND PERSONAL PROTECTIVE ITEMS

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

FIRE EXTINGUISHER AND FIRST AID KIT

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

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

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SAFETY GENERAL PRECAUTIONS

KEEP MACHINE CLEAN

If water gets into the electrical system, there is a hazard that it
will cause malfunctions or misoperation. Do not use water or
steam to wash the electrical system (sensors, connectors).
If inspection and maintenance is carried out when the machine
is still dirty with mud or oil, there is a hazard that you will slip and
fall, or that dirt or mud will get into your eyes. Always keep the
machine clean.

INSIDE OPERATOR'S COMPARTMENT

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

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT

Before leaving the operator's seat for any reason (such as
carrying out maintenance), always lower the work equipment
completely to the ground and set safety lock lever (1) to the
LOCK position (L). Keep the brake pedal depressed, set to
brake lock lever (2) to the LOCK position (L) to lock the brake
pedal, then stop the engine.
If you accidentally touch the control levers are touched when
they are not locked, there is danger that the machine may
suddenly move and cause serious personal injury or property
damage.

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GENERAL PRECAUTIONS SAFETY

Before leaving the machine, always lower the work equipment

completely to the ground and set safety lock lever (1) to the
LOCK position (L). Keep the brake pedal depressed, set brake
lock lever (2) to the LOCK position (L) to lock the brake pedal,
then stop the engine.
Use the key to lock all equipment. Always take the key with you,
and keep it in the specified place.

HANDRAILS AND STEPS

To prevent personal injury caused by slipping or falling off the machine, always do as follows.
Use the handrails and steps marked by arrows in the diagram on
the right when getting on or off the machine.

To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands and
one foot) with the handrails and steps (including the track shoe)
to ensure that you support yourself.
Do not grip the control levers when getting on or off the machine.
Never climb on the engine hood or covers where there are no
non-slip pads.
Before getting on or off the machine, check the handrails and
steps (including the track shoe). If there is any oil, grease, or
mud on the handrails or steps (including the track shoe), wipe it
off immediately. Always keep these parts clean. Repair any
damage and tighten any loose bolts.
Do not get on or off the machine while holding tools in your hand.

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SAFETY GENERAL PRECAUTIONS

MOUNTING AND DISMOUNTING

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

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

CRUSHING OR CUTTING PREVENTION

The clearance around the work equipment will change according to the movement of the link. If you get caught, this
may lead to serious personal injury. Do not allow anyone to approach any rotating or telescoping part.

PREVENTION OF BURNS
Hot coolant
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap by
hand before starting the operation. Even when the coolant has
cooled down, loosen the cap slowly to relieve the pressure
inside the radiator before removing the cap.
Hot oil
To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to at temperature where
it is possible to touch the cap or plug by hand before starting the
operation. Even when the oil has cooled down, loosen the
cap or plug slowly to relieve the internal pressure before
removing the cap or plug.

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GENERAL PRECAUTIONS SAFETY

FIRE PREVENTION
Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly
flammable and can be hazardous. To prevent fire, always
observe the following:
Do not smoke or use any flame near fuel or oil.
Stop the engine before refueling.
Do not leave the machine while adding fuel or oil.
Tighten all fuel and oil caps securely.
Do not spill fuel on overheated surfaces or on parts of the
electrical system.
Use well-ventilated areas for adding or storing oil and fuel.
Keep oil and fuel in the determined place and do not allow
unauthorized persons to enter.
After adding fuel or oil, wipe up any spilled fuel or oil.
When carrying out grinding or welding work on the chassis,
move any flammable materials to a safe place before
starting.
When washing parts with oil, use a non-flammable oil. Diesel
oil and gasoline may catch fire, so do not use them.
Put greasy rags and other flammable materials into a safe
container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.

Fire caused by accumulation of flammable material.

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

Fire coming from electric wiring

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

Fire coming from hydraulic line

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

Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with
anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion that may
cause serious injury.
When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.

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SAFETY GENERAL PRECAUTIONS

ACTION IF FIRE OCCURS

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

WINDOW WASHER LIQUID

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

PRECAUTIONS WHEN USING ROPS

Install ROPS when working in places where there is danger of
falling rocks, such as in mines and quarries, or in places where
there is danger of rolling over.
If ROPS is installed, do not remove it when operating the
machine.
ROPS is installed to protect the operator when machine rolls
over. When machine rolls over, ROPS supports its weight and
absorbs its impact energy.
If ROPS is modified, its strength may be reduced. When
modifying, consult your Komatsu distributor.
If ROPS is deformed by falling objects or by rolling over, its strength lowers and its design functions cannot be
maintained. In this case, be sure to ask your Komatsu distributor about repair method.
Even if ROPS is installed, it does not work normally, if your seat belt is not fastened. Be sure to fasten your seat
belt when operating machine.

PRECAUTIONS FOR ATTACHMENTS

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

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

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GENERAL PRECAUTIONS SAFETY

SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass, there
is a hazard of fire, so be careful when operating.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not carry out operations at places where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or damage any of these lines.
Take action to prevent unauthorized people from approaching
the jobsite.
When working on public roads, position flagmen and erect
barriers to ensure the safety of passing traffic and pedestrians.
When traveling or operating in shallow water or on soft ground,
check the shape and condition of the bedrock, and the depth
and speed of flow of the water before starting operations.

WORKING ON LOOSE GROUND

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

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

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

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SAFETY GENERAL PRECAUTIONS

ENSURE GOOD VISIBILITY

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

VENTILATION FOR ENCLOSED AREAS

Exhaust fumes from the engine can kill.
If it is necessary to start the engine within an enclosed area, or
when handling fuel, flushing oil, or paint, open the doors and
windows to ensure that adequate ventilation is provided to
prevent gas poisoning.

CHECKING SIGNALMAN'S SIGNALS AND SIGNS

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

EMERGENCY EXIT FROM OPERATOR'S CAB

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

BE CAREFUL ABOUT ASBESTOS DUST

Asbestos dust in the air can cause lung cancer if it is inhaled. There
is danger of inhaling asbestos when working on jobsites handling
demolition work or work handling industrial waste. Always observe
the following.
Spray water to keep down the dust when cleaning. Do not use
compressed air for cleaning.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position. All
workers should use an approved respirator.
Do not allow other persons to approach during the operation.
Always observe the rules and regulations for the work site and
environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use
genuine Komatsu parts.

2 - 15
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PRECAUTIONS FOR OPERATION SAFETY

PRECAUTIONS FOR OPERATION

STARTING ENGINE
If there is a warning tag hanging from the work equipment control
lever, do not start the engine or touch the levers .

CHECKS BEFORE STARTING ENGINE

Carry out the following checks before starting the engine at the beginning of the day's work.
Remove all dirt from the surface of the window glass to ensure a good view.
Remove all dirt from the surface of the lens of the front lamps and working lamps, and check that they light up
correctly.
Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check
for damage to the electric wiring.
Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no damage
or wear to the seat belt or mounting clamps.
Check that the gauges work properly, check the angle of the lights and working lamps, and check that the control
levers are all at the neutral position.
Adjust the mirror to a position which gives a good view to the rear from the operator's seat.
Check that there are no persons or obstacles above, below, or in the area around the machine.

PRECAUTIONS WHEN STARTING

Start and operate the machine only while seated.
Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious
bodily injury or fire.
When starting the engine, sound the horn as a warning.
Do not allow anyone apart from the operator to ride on the machine.

2 - 16
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SAFETY PRECAUTIONS FOR OPERATION

PRECAUTIONS IN COLD AREAS

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

2 - 17
.

PRECAUTIONS FOR OPERATION SAFETY

OPERATION

CHECKS BEFORE OPERATION

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
Always fasten your seat belt.
Check the operation of travel, steering and brake systems, and
work equipment control system.
Check for any abnormality in the sound of the machine,
vibration, heat, smell, or gauges; check also that there is no
leakage of oil or fuel.
If any abnormality is found, carry out repairs immediately.

PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE

Before travelling, check again that there is no one in the
surrounding area, and that there are no obstacles.
Before travelling, sound the horn to warn people in the area.
Always operate the machine only when seated.
Do not allow anyone apart from the operator to ride on the
machine.
Check that the back-up alarm (alarm buzzer when machine
travels in reverse) works properly.
Fix the operator's compartment doors and windows in position
securely.
If there is an area to the rear of the machine which cannot be
seen, position a signal person. Take special care not to hit other
machines or people when turning or swinging the machine.
Always be sure to carry out the above precautions even when the
machine is equipped with mirrors.

PRECAUTIONS WHEN TRAVELING

When traveling on level ground, keep the work equipment at a
height of 40 to 50 cm (1.6 to 2.0 in) from the ground.
When traveling on rough ground, travel at low speed and do not
operate the steering suddenly. There is danger that the machine
may turn over. The work equipment may hit the ground surface
and cause the machine to lose its balance, or may damage the
machine or structures in the area.

2 - 18
.

SAFETY PRECAUTIONS FOR OPERATION

Avoid traveling over obstacles when possible. If the machine

has to travel over an obstacle, keep the work equipment close
to the ground and travel at low speed. Never travel over
obstacles which make the machine tilt strongly to one side.
When traveling or carrying out operations, always keep a safe
distance from people, structures, or other machines to avoid
coming into contact with them.
When passing over bridges or structures, check first that the
structure is strong enough to support the weight of the machine.
When traveling on public roads, check first with the relevant
authorities and follow their instructions.
When operating in tunnels, under bridges, under electric wires,
or other places where the height is limited, operate slowly and
be extremely careful not to let the work equipment hit anything.
Do not approach the edge of a cliff carelessly. When dropping soil over a cliff for banking or reclamation, leave
soil of one scoop at the edge of the cliff and push it with the next scoop.
When the machine passes over the top of a hill or when a load is dumped over a cliff, the load is suddenly reduced,
and there is danger that the travel speed rises suddenly. To prevent this, lower the travel speed.
If the machine moves with only either side of the blade loaded, its tail may swing. Take care.

TRAVELING ON SLOPES
To prevent the machine from tipping over or slipping to the side, always do as follows.
Keep the work equipment approx. 20 to 30 cm (8 to 12 in) above
the ground. In case of emergency, lower the work equipment to
the ground immediately to help stop the machine.
When traveling down slopes, do not shift gear or set the
transmission to neutral. This is extremely dangerous as it
becomes impossible to use the engine as a brake. Always set
the transmission in a low speed range and use the service brake
and engine to brake the machine as necessary.
Always travel straight up or down a slope. Traveling at an angle
or across the slope is extremely dangerous.
Do not turn on slopes or travel across slopes. Always go down
to a flat place to change the position of the machine, then travel
on to the slope again.
Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard that
the machine may slip.

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

OPERATE CAREFULLY ON SNOW

Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine,
and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly
careful when working on slopes.

2 - 19
.

PRECAUTIONS FOR OPERATION SAFETY

With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful
not to leave the road shoulder or to get trapped in a snow drift.
When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be
seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations
carefully.
When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and use the engine
as a brake while appling the foot brake intermittently (depress the brake intermittently several times). If
necessary, lower the blade to the ground to stop the machine.

PARKING MACHINE
Park the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground.

When leaving the machine, first set the steering, directional, and
speed lever to the N position, then set the blade control lever to
the HOLD position and set safety lock lever (1) to the LOCK
position (L).
Next, keep the brake pedal depressed, set brake lock lever (2)
to the LOCK position (L) to lock the brake pedal, then stop the
engine.
Always close the operator's cab door, and use the key to lock all
the equipment in order to prevent any unauthorized person from
moving the machine. Always remove the key, take it with you,
and leave it in the specified place.

2 - 20
.

SAFETY PRECAUTIONS FOR OPERATION

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

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

2 - 21
.

PRECAUTIONS FOR OPERATION SAFETY

TRANSPORTATION

LOADING AND UNLOADING

When loading or unloading the machine, mistaken operation may
bring the hazard of the machine tipping over or falling, so particular
care is necessary. Always do as follows.
Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of the road or cliff.
Always use ramps of adequate strength. Be sure that the ramps
are wide, long, and thick enough to provide a safe loading slope.
Take suitable steps to prevent the ramps from moving out of
position or coming off.
Be sure the ramp surface is clean and free of grease, oil, ice and
loose materials. Remove dirt from machine-tracks. On a rainy
(1) Blocks
day, in particular, be extremely careful since the ramp surface is
(2) Ramp
slippery.
(3) Width of ramps: Same width as track
Run the engine at low speed and travel slowly.
(4) Angle of ramps: 15°
When on the ramps, do not touch any other parts.
(5) Block
Never correct your steering on the ramps. If necessary, drive off
the ramps, correct the direction, then enter the ramps again.
The center of gravity of the machine will chenge suddenly at the joint between the ramps and the track or trailer,
and there is danger of the machine losing its balance. Travel slowly over this point.
When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and
grade.
For machines equipped with a cab, always lock the door after boarding the machine. If this is not done, the door
may suddenly open during transportation.
Refer to "TRANSPORTATION (PAGE 3-62)".

SHIPPING
When shipping the machine on a trailer, do as follows.
The weight, transportation height, and overall length of the machine differ according to the work equipment, so
be sure to confirm the dimensions.
When passing over bridges or structures on private land, check first that the structure is strong enough to support
the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their
instructions.
For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-62)" in the OPERATION section.

2 - 22
.

SAFETY PRECAUTIONS FOR OPERATION

BATTERY

BATTERY HAZARD PREVENTION

Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.
Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.
Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause
an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the electrolyte
level to the UPPER LEVEL line.
When working with batteries, always wear safety glasses and rubber gloves.
Never smoke or use any flame near the battery.

If you spill acid on your clothes or skin, immediately flush the

area with large amount of water.
If acid gets into your eyes, flush them immediately with large
amount of water and seek medical attention.

Before working with batteries, turn the starting switch to the OFF position.

As there is a hazard that sparks will be generated, always do as follows.

Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other
metal objects lying around near the battery.
Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals securely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take
it to a well-ventilated place, and remove the battery caps before charging it.
Tighten the battery caps securely.
Install the battery securely to the determined place.

2 - 23
.

PRECAUTIONS FOR OPERATION SAFETY

STARTING WITH BOOSTER CABLE

If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
When starting with a booster cable, carry out the starting
operation with two workers (one worker sitting in the operator's
seat and the other working with the battery).
When starting from another machine, do not allow the two
machines to touch.
When connecting the booster cables, turn the starting switch
OFF for both the normal machine and problem machine. There
is a hazard that the machine will move when the power is
connected.
Be sure to connect the positive (+) cable first when installing the
booster cables. Disconnect the negative (-) cable (ground side)
first when removing them.
When removing the booster cables, be careful not to let the
booster cable clips touch each other or to let the clips touch the
machine.
Always wear safety goggles and rubber gloves when starting
the engine with booster cables.
When connecting a normal machine to a problem machine with
booster cables, always use a normal machine with the same
battery voltage as the problem machine.
For details of the starting procedure when using booster cables,
see "STARTING ENGINE WITH BOOSTER CABLE (PAGE
3-73)" in the OPERATION section.

2 - 24
.

SAFETY PRECAUTIONS FOR OPERATION

TOWING

WHEN TOWING
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection
or inspection of the wire rope.
For towing method, see section "MACHINE TOWING METHOD (PAGE 3-70)".
Always wear leather gloves when handling wire rope.
Connect a wire rope to the part indicated with the arrow in the
diagram at right.
During the towing operation, never stand between the towing
machine and the machine being towed.
Never tow a machine on a slope.

Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope may
break during the towing operation.

2 - 25
.

PRECAUTIONS FOR MAINTENENCE SAFETY

PRECAUTIONS FOR MAINTENANCE

WARNING TAG
Always attach the "DO NOT OPERATE" warning tag to the work
equipment control lever in the operator's cab to alert others that
you are performing service or maintenance on the machine.
Attach additional warning tags around the machine if necessary.
Warning tag Part No. 09963-03001
Keep this warning tag in the tool box while it is not used. If there
is no toolbox, keep the tag in the operation manual pocket.
If others start the engine, or touch or operate the work
equipment control lever while you are performing service or
maintenance, you could suffer serious injury or property
damage.

KEEP WORK PLACE CLEAN AND TIDY

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

APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
When working with others, misunderstandings between workers can lead to serious accidents.

2 - 26
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SAFETY PRECAUTIONS FOR MAINTENENCE

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

Stop the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground and stop
the engine.

Operate work control lever (1) fully to the RAISE and LOWER
positions 2 or 3 times to release the remaining pressure in the
hydraulic circuit, then set safety lock lever (2) to the LOCK
position (L).

Keep the brake pedal depressed, set brake lock lever (3) to the
LOCK position (L) to lock the brake pedal.

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

2 - 27
.

PRECAUTIONS FOR MAINTENENCE SAFETY

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent injury, do not carry out maintenance with the engine
running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and do as
follows.
One worker must always sit in the operator's seat and be ready
to stop the engine at any time. All workers must maintain
contact with the other workers.

Set safety lock lever (1) to the LOCK position (L).

Keep the brake pedal depressed, set brake lock lever (2) to the
LOCK position (L) to lock the brake pedal.

When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in
the parts, so be careful not to come close.
Do not touch any control levers. If any control lever must be operated, give a signal to the other workers to warn
them to move to a safe place.
Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.

2 - 28
.

SAFETY PRECAUTIONS FOR MAINTENENCE

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

NO UNAUTHORIZED PERSONNEL INTO AREA

Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.

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

WORK UNDER THE MACHINE

If it is necessary to go under the work equipment or the machine
to carry out service and maintenance, support the work
equipment and machine securely with blocks and stands strong
enough to support the weight of the work equipment and
machine.
It is extremely dangerous to work under the machine if the track
shoes are lifted off the ground and the machine is supported
only with the work equipment. If any of the control levers is
touched by accident, or there is damage occurring to the
hydraulic piping, the work equipment or the machine will
suddenly drop. This is extremely dangerous. Never work under
the work equipment or the machine.

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

2 - 29
.

PRECAUTIONS FOR MAINTENENCE SAFETY

PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may fly out or metal particles may be
scattered. This may lead to serious injury. Always do as follows.
If hard metal parts such as pins, bucket teeth, cutting edges, or
bearings are hit with a hammer, there is a hazard that pieces
might be scattered and cause injury. Always wear safety
goggles and gloves.
When hitting pins or bucket teeth, there is a hazard that broken
pieces might be sent flying and injure people in the surrounding
area. Always check that there is no one in the surrounding area.
There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.

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

REMOVING BATTERY TERMINAL

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the
battery to prevent the flow of current.

PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION

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

DO NOT DISASSEMBLE RECOIL SPRING

Never attempt to disassemble the recoils spring assembly. It contains a spring under high pressure which serves
as a shock absorber for the idler. If it is disassembled by mistake, the spring will fly out and cause serious injury.
When it becomes necessary to disassemble it, ask your Komatsu distributor to do the work.

2 - 30
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SAFETY PRECAUTIONS FOR MAINTENENCE

PRECAUTION WITH HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury, so always do as follows.
Do not carry out inspection or replacement work when the hydraulic system is under pressure.
If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping
and hoses and for swelling in the hoses.
When carry out inspection, wear safety glasses and leather gloves.
There is a hazard that high-pressure oil leaking from small holes
may penetrate your skin or cause blindness if it contacts your
eyes directly. If you are hit by a jet of high-pressure oil and suffer
injury to your skin or eyes, wash the place with clean water, and
consult a doctor immediately for medical attention.

HANDLING HIGH-PRESSURE HOSES

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found,
stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
Damaged or leaking hydraulic fitting.
Frayed or cut covering or exposed reinforcement wire layer.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.

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

MAINTENANCE FOR AIR CONDITIONER

If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite.
Never touch refrigerant.

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PRECAUTIONS FOR MAINTENENCE SAFETY

COMPRESSED AIR
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

In order for the machine to be operated safety for a long time, it is necessary to add oil and to carry out service
and maintenance at periodic intervals. In order to further increase safety, components with a strong relationship
to safety, such as hoses and seat belts, must be replaced at periodic intervals.
Replacement of safety critical parts: See "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
(PAGE 4-13)".
The material of these components naturally changes over time, and repeated use causes deterioration, wear, and
fatigue. As a result, there is a hazard that these components may fail and cause serious injury or death. It is
difficult to judge the remaining life of these components from external inspection or the feeling when operating,
so always replace them at the specified interval.
Replace or repair safety-critical parts if any defect is found, even when they have not reached the time specified
interval.

2 - 32
.

3-1
.

GENERAL VIEW OPERATION

GENERAL VIEW
GENERAL VIEW OF MACHINE

(1) Blade (5) Sprocket

(2) Tilt cylinder (6) Track frame
(3) Lift cylinder (7) Idler
(4) Track shoe (8) Angle cylinder

3-2
.

OPERATION GENERAL VIEW

GENERAL VIEW OF CONTROLS AND GAUGES

(1) Fuel control lever (11) Engine water temperature gauge

(2) Speed stage indicator windows (12) Fuel gauge
(3) Horn switch (13) Service meter
(4) Steering, directional and gear shift lever (14) Glow signal
(5) Blade control lever (15) Lamp switch
(6) Brake pedal (16) Starting switch
(7) Brake lock lever (17) Air cleaner clogged warning lamp
(8) Inching pedal (18) Engine oil pressure warning lamp
(9) Safety lever (for blade control lever) (19) Charge level caution lamp
(10) Safety lever (for steering, directional and gear
shift lever)

3-3
.

EXPLANATION OF COMPONENTS OPERATION

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

FRONT PANEL

(A) Emergency items (C) Inspection and maintenance items

(B) Caution items (D) Meter display

3-4
.

OPERATION EXPLANATION OF COMPONENTS

EMERGENCY ITEMS
CAUTION
If the caution lamp lights up, stop the engine immediately or run it at low idling, and inspect and carry out the necessary action
for the problem location immediately.

These are items that should be observed when the engine is running. If any abnormality occurs, the caution lamp
for the problem location lights up. Carry out the necessary action immediately.

(1) Engine oil pressure caution lamp

ENGINE OIL PRESSURE CAUTION LAMP

This lamp (1) warns that the engine lubricating oil pressure has
dropped.

This lights up when the engine is stopped and the starting switch
is at the ON position. It goes out when the engine starts.

When engine is running

This lights up when the engine lubricating oil pressure goes down.

3-5
.

EXPLANATION OF COMPONENTS OPERATION

CAUTION ITEMS
CAUTION
If the caution lamp lights up, carry out inspection and maintenance of the problem location as soon as possible.

These are items that should be observed when the engine is running. If any abnormality occurs, the display shows
the item requiring action to be taken as soon as possible.
When there is any abnormality, the caution lamp for the problem location lights up.

(1) Charge level caution lamp

CHARGE LEVEL CAUTION LAMP

This lamp (1) lights up when the engine is running to inform the
operator that there is a problem with the charging system.

This lights up when the engine is stopped and the starting switch
is at the ON position. It goes out when the engine starts.

When engine is running

This lights up if any abnormality occurs in the charging circuit.

3-6
.

OPERATION EXPLANATION OF COMPONENTS

INSPECTION AND MAINTENANCE ITEMS

CAUTION
If the caution lamp lights up, stop work immediately and carry out the following action.

(1) Air cleaner clogging caution lamp

AIR CLEANER CLOGGING CAUTION LAMP

This lamp (1) lights up if there is clogging of the air cleaner element.

If it lights up, clean or replace the air cleaner element.

After cleaning, check that the caution lamp has gone out.

3-7
.

EXPLANATION OF COMPONENTS OPERATION

METER DISPLAY

(1) Engine water temperature gauge (3) Service meter

(2) Fuel gauge (4) Heater signal

ENGINE WATER TEMPERATURE GAUGE

This gauge (1) shows the temperature of the engine coolant.
When the indicator is in green range (A) during operation, the water
temperature is normal.
If the indicator enters red range (B), stop the machine, run the
engine at low idling, and wait for the indicator to go down to green
range (A).
After starting the engine, warm it up until the indicator enters green
range (A).

FUEL GAUGE
When the starting switch is at the ON position, this meter (2) shows
the amount of fuel in the fuel tank.
The meter shows the fuel level as follows.
F: Full tank
E: Empty (there is less than 14 liters (3.70 US gal) of fuel
remaining, so add fuel)
Always fill the fuel tank after completing the day's operations.

3-8
.

OPERATION EXPLANATION OF COMPONENTS

SERVICE METER
This meter (3) displays of the total number of hours of operation.
Use this display to set to the periodic maintenance intervals.
If the engine is running, the service meter advances even if the
machine is not being operated.
When the engine is running, operation display (A) rotates to show
that the meter is advancing.
When the engine is running, meter (B) advances by 1 for every
1/10 hour (every 6 minutes) of operation, regardless of the engine
speed.

HEATER SIGNAL
This signal (7) informs the operator that the electric heater is in the
preheating condition.
When the starting switch is turned to HEAT, preheating is started.
When the starting switch key is released, it returns automatically to
the OFF position.

3-9
.

EXPLANATION OF COMPONENTS OPERATION

SWITCHES

(1) Starting switch (3) Horn switch

(2) Lamp switch

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

(A): OFF position

At this position, the starting switch key can be inserted and
removed. When the starting switch key is turned to this position,
the power to the electrical system is switched off and the engine
stops.

(B): ON position
Electric current flows to the charging and lamp circuits, and the
feed pump is actuated. Keep the key at the ON position when the
engine is running.

(C): START position

Turn the starting switch key to this position to start the engine. Hold it in the START position when cranking the
engine. Release the key immediately when the engine starts. The key will return to the ON position (B).

(D): HEAT position

Turn the key to the HEAT position when starting the engine in cold weather.
If the key is held at HEAT position (D), the electric heater becomes hot and the heater signal glows red. When the
heater signal glows red, release the key immediately.
When the key is released, it returns to OFF position (A), so turn it immediately to the START position (C) to start the
engine.

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.

OPERATION EXPLANATION OF COMPONENTS

LAMP SWITCH
This switch (2) lights up the head lamps, rear working lamp, and
the panel lamp.
OFF position: Lamps are OFF
Position 1: Head lamps and instrument panel lamp light up
Position 2: Rear working lamp lights up in addition to the head
lamps and instrument panel lamp

HORN SWITCH
This switch (3) is at the front of the left armrest. Press it to sound
the horn.

3 - 11
.

EXPLANATION OF COMPONENTS OPERATION

CONTROL LEVERS AND PEDALS

(1) Safety lever (for blade control lever) (5) Brake pedal
(2) Safety lever (for steering, directional and gear (6) Brake lock lever
shift lever) (7) Inching pedal
(3) Steering, directional and gear shift lever (8) Blade control lever
(4) Fuel control lever

SAFETY LEVER (FOR BLADE CONTROL LEVER)

WARNING
When standing up from the operator's seat, set the safety lock lever securely to the LOCK position.
If the lever is not at the LOCK position and the blade control lever is touched by mistake, it may lead to serious personal injury.
If the safety lock lever is not placed securely at the LOCK position, the blade control lever may move and cause serious
personal injury. Check that the safety lock lever is at the LOCK position.
When parking the machine or carrying out maintenance, always lower the work equipment completely to the ground and set
the lever to the LOCK position.

This is the locking device of blade control lever (1).

(L): Lock position
(F): Free position

When the lever is set to the LOCK position, the blade operation is
locked.

REMARK
When the blade control lever is at the FLOAT position and the
safety lock lever is operated to the LOCK position, the blade
control lever is automatically returned to the HOLD position.

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.

OPERATION EXPLANATION OF COMPONENTS

SAFETY LEVER (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER)

WARNING
When standing up from the operator's seat, set the safety lock lever securely to the LOCK position.
If the lever is not locked, and the steering, directional and gear shift lever is touched by mistake, it may cause serious personal
injury.
If the safety lock lever is not placed securely at the LOCK position, the steering, directional and gear shift lever may move and
cause serious personal injury. Check that the safety lock lever is at the LOCK position.
When parking the machine or carrying out maintenance, always set the lever to the LOCK position.

This locks the steering, directional and gear shift lever (2).
(L): Lock position
(F): Free position

Set the steering, directional and gear shift lever at the N position,
then operate the safety lock lever to the LOCK position.
When the safety lock lever is operated to the LOCK position, the
operation of the steering, directional and gear shift lever is locked.

REMARK
If the steering, directional and gear shift lever is at the
FORWARD or REVERSE position and the safety lock lever is
operated to the LOCK position, the steering, directional and
gear shift lever is automatically returned to the N position.
If the safety lock lever is not at the LOCK position, the engine
will not start.

3 - 13
.

EXPLANATION OF COMPONENTS OPERATION

JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER)

This lever (3) is used to select the direction of travel, to shift gear, to steer the machine, and to adjust travel speed.

Forward-reverse shifting
Position (A): FORWARD
Position (B): REVERSE
Position (N): NEUTRAL
Operate the lever to the front to travel FORWARD.
Operate the lever to the rear to travel in REVERSE.

Steering
Position (L): Left turn
Position (R): Right turn
If the lever is set in the forward or reverse travel position and operated to the left or right, the machine will turn in the
direction that the lever is operated. The turning radius changes according to the amount that the lever is operated.
If the lever is operated fully to the left or right, the turning radius will become smaller.

REMARK
When you are steering, if you release the lever, it will return to
the center position and the machine will travel in a straight line.
When you are steering, support your hand with the lever guide
to make it easier to carry out the turning operation.

Gear shifting
Turn the steering, directional and gear shift lever within a range of
15° to shift the gear. A 3-speed machine is available as an option.
Position (C): 1st
Position (D): 2nd
Position (E): 3rd (If equipped)

REMARK
When the gear is shifted, the speed range is displayed in the
display window (F) at the rear of the lever.
1: 1st
2: 2nd
3: 3rd (If equipped)

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.

OPERATION EXPLANATION OF COMPONENTS

FUEL CONTROL LEVER

This lever (4) is used to control the engine speed and output.
(A) Low idling position: Push the lever forward fully.
(B) High idling position: Pull the lever fully.

BRAKE PEDAL

WARNING
Do not place your foot on this pedal unnecessarily.

Depress this pedal (5) to apply both the left and right brakes.

BRAKE LOCK LEVER

WARNING
When parking the machine, always lock the brake pedal.

This lever (6) is the lock device for the brake pedal. Use it when
parking the machine.
(L): LOCK position
The brake pedal is locked.
(F): FREE position
The brake pedal lock is released.

When locking brake pedal

There are two ways of locking the brake pedal.
Keep the brake pedal depressed and pull the brake lock lever.
Pull the brake lock lever, then depress the brake pedal strongly.

When releasing brake pedal

Depress the brake pedal, then push in the brake lock lever.

3 - 15
.

EXPLANATION OF COMPONENTS OPERATION

INCHING PEDAL

WARNING
Do not place your foot on this pedal unnecessarily.

This pedal (7) disconnects and connects the power from the
engine. Use it for inching operations.
If the pedal is depressed half way, the clutch will be partially
engaged; if it is depressed fully, the power from the engine is cut.
Use this when approaching the target object.

BLADE CONTROL LEVER

This lever (8) is used to lift, tilt, or angle the blade.

LIFTING CONTROL
(A) RAISE:
(B) HOLD: Blade is stopped and held in this position.
(C) LOWER:
(D) FLOAT: Blade will move freely according to external force.

REMARK
When released from FLOAT position, this lever will not return to
HOLD position, so it must be moved back by hand.
Before starting the engine, check that the blade control lever is
at the HOLD position.

3 - 16
.

OPERATION EXPLANATION OF COMPONENTS

TILTING CONTROL
(B) HOLD: Blade is stopped and held in this position.
(E) LEFT TILT
(F) RIGHT TILT

The tilt amount for each model is shown below.

Machine model Tilt

D21A 250 mm (9.9 in)
D21P 280 mm (11.0 in)

ANGLING CONTROL
(Power angle, power tiltdozer only)
Turn the lever to the right or left to angle the blade.
(G) LEFT ANGLE
(H) HOLD: Blade is stopped and held in this position.
(I) RIGHT ANGLE
The angle amount is 25° on both the left and right.

3 - 17
.

EXPLANATION OF COMPONENTS OPERATION

FUSE
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.

The fuses protect the electrical equipment and wiring from burning
out.
If the fuse becomes corroded, or white powder can be seen, or the
fuse is loose in the fuse holder, replace the fuse.
Replace the fuse with another of the same capacity.

FUSE CAPACITY AND CIRCUIT NAME

Fuse
No. Circuit name
capacity
(1) 20A Head lamp, Rear working lamp
(2) 10A Horn
(3) 10A Back-up alarm (if equipped)
Water temperature gauge, Fuel gauge,
(4) 10A
Caution lamp
Engine stop solenoid
(5) 30A Air cleaner clogged sensor
Fuel feed pump

DOOR POCKET
There is a pocket on the back of the operator's seat.
Keep the Operation & Maintenance manual in this pocket so that
the operator can read it whenever necessary.

3 - 18
.

OPERATION OPERATION

OPERATION
CHECK BEFORE STARTING ENGINE, ADJUST

WALK-AROUND CHECK
Before starting the engine, look around the machine and under the machine to check for loose nuts 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 accumulation of dust at places which reach high temperatures.

WARNING
Remove any flammable materials from around the battery or engine muffler or other high temperature engine parts. Leakage of
fuel or oil will cause the machine to catch fire. Check carefully, and be sure to repair any abnormalities, or please contact your
Komatsu distributor.

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

Carry out the following inspections and cleaning every day before starting the engine for the day's work.

1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses
Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If
any abnormality is found, repair it.

2. Remove the dirt from around the engine, battery, and radiator.
Check that there is no dirt accumulated around the engine or radiator. Check also that there is no flammable
material (dry leaves, twigs, etc.) around the battery, engine muffler, turbocharger, or other high temperature
parts of the engine. If any dirt or flammable materials are found, remove them.

3. Check for leakage of water or oil around engine

Check that there is no leakage of oil from the engine or leakage of water from the cooling system. If any
abnormality is found, repair it.

4. Check that there is no oil leakage from the transfer case (including the bevel gear case), transmission case,
steering clutch case, final drive case, hydraulic tank, hoses, and joints
Check that there is no oil leakage. If any leakage is found, repair the location of the leakage.
When checking for oil leakage, check for traces of oil leakage from the undercover and for signs of oil dripping
on the ground.

5. Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers.
If any abnormality is found, repair it.

6. Check for abnormality in handrails, steps, loose bolts.

If any abnormality is found, repair it. Tighten any loose bolts.

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.

3 - 19
.

OPERATION OPERATION

8. Seat belt and mounting clamps

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

3 - 20
.

OPERATION OPERATION

CHECK BEFORE STARTING

Always carry out the items of the checks in this section before starting the engine each day.

CHECK COOLANT LEVEL, ADD WATER

WARNING
Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check
the sub tank.
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
If the cap is removed to check the coolant level in this condition, there is a hazard of burns. Wait for the temperature to go
down, then turn the cap slowly to release the pressure before removing it.

1. Open the cover at the top front of the machine and check that
the level of the coolant in sub tank (1) (see diagram on right) is
between the FULL and LOW lines. If the coolant level is low,
add water to the FULL line through the water filler of sub tank
(1).

REMARK
In summer, the coolant may overflow from the sub-tank drain hose.
This is no problem. It occurs because too much coolant has been
added.

2. After adding coolant, 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 filling with water, close the top cover.

3 - 21
.

OPERATION OPERATION

CHECK FUEL LEVEL, ADD FUEL

WARNING
When adding fuel, never spill the fuel or let it overflow. It will cause fire.
If any fuel has spilled, wipe it up completely. If fuel has spilled over soil or sand, remove that soil or sand.
Fuel is highly flammable and dangerous. Never bring flames near fuel.

1. Turn the engine starting switch to the ON position and check

the fuel level gauge (G) on the monitor panel for fuel level.
After checking, turn the switch back to the OFF position.

2. After completing work, fill the fuel tank through fuel filler port
(F).
Fuel capacity: 60 liters (15.85 US gal)

3. After adding fuel, tighten the cap securely.

REMARK
If breather hole (1) in the cap is clogged, the pressure in the tank
will drop and fuel will not flow. Clean the hole from time to time.

3 - 22
.

OPERATION OPERATION

CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the
temperature to go down before starting the operation.

1. Open the cover on top of the engine hood.

2. Remove dipstick (G) and wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out again.
4. The oil level should be between the H and L marks on dipstick
(G).
If the oil level is below the L mark, add oil through oil filler (F).

5. If the oil is above the H mark, drain the excess engine oil from
drain plug (P), and check the oil level again.
6. If the oil level is correct, tighten the oil filler cap securely, then
close the top cover.

REMARK
If the machine is at an angle, make it horizontal before
checking.
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.

3 - 23
.

OPERATION OPERATION

CHECK OIL LEVEL IN BEVEL GEAR CASE, TRANSFER CASE, ADD OIL

WARNING
The parts and oil are at high temperature after the engine is stopped, and
may cause serious burns. Wait for the temperature to go down before
starting the operation.

1. Remove dipstick (G) and wipe the oil off with a cloth.
2. Insert dipstick (G) fully in the oil filler pipe, then take it out again.
3. The oil level should be between the H and L marks on dipstick
(G).
If the oil level is below the L mark, add oil through oil filler (F).
4. If the oil is above the H mark, drain the excess engine oil from
drain plug (P), and check the oil level again.
5. If the oil level is correct, insert dipstick (G) fully into the dipstick
guide again.

REMARK
If the machine is at an angle, make it horizontal before
checking.
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.

CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to
go down before starting the operation.

1. Pull up the notched portion of the floor mat.

2. Remove dipstick (G) and wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out again.
4. The oil level should be between the H and L marks on dipstick
(G).
If the oil level is below the L mark, add oil through oil filler (F).
5. If the oil is above the H mark, drain the excess engine oil from
drain plug (P), and check the oil level again.
6. If the oil level is correct, insert dipstick (G) fully into the dipstick
guide again.

REMARK
If the machine is at an angle, make it horizontal before checking.
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the
engine before checking.

3 - 24
.

OPERATION OPERATION

CHECK BRAKE PEDAL TRAVEL

WARNING
If travel (A) of the brake pedal is not within a range of 98 to 134 mm (3.86 to 5.28 in) (either above or below this range), the effect
of the brake and the steering will be too strong or too weak. If the travel of the brake pedal is 135 mm (5.32 in) or more, carry out
adjustment.

1. Depress the brake pedal all the way until it stops.

2. Check that travel (A) at the bottom tip of the pedal is 98 to 134
mm (3.86 to 5.28 in).
3. If it is 135 mm (5.32 in)or more, or the effect is poor, carry out
adjustment. For details, see "ADJUST BRAKE PEDAL
(TEST, ADJUST STEERING BRAKE) (PAGE 4-35)".
If it is less than 98 mm (3.86 in), please contact your Komatsu
distributor.

CHECK, DRAIN WATER SEPARATOR

The water separator separates the water from the fuel.
Check if there is any accumulated water. Drain any accumulated water.

1. Open the inspection window in the right engine side cover.

2. If red ring (1) in the water separator has sunk to the bottom of
element cup (2), there is no need to drain the water.
If red ring (1) in the water separator is floating, there is water
accumulated up to the bottom of the ring, so drain the water as
follows.
3. Set handle (3) to the OFF position (A).
4. Loosen drain plug (4), drain the accumulated water until red
ring (1) reaches the bottom, then tighten plug (4).
5. Set handle (3) to the ON position (B).
6. rain any water or sediment from fuel tank. For details, see
"DRAIN WATER, SEDIMENT FROM FUEL TANK (PAGE
4-39)".
7. After the water has been drained from the water separator,
there will be air in the fuel system, so bleed the air.
For details of the method of bleeding the air, see "METHOD OF
USING AUTOMATIC AIR BLEED MECHANISM (PAGE
4-46)".

3 - 25
.

OPERATION OPERATION

DOES THE HORN SOUND NORMALLY?

Check that the horn sounds. If it does not sound at all or the sound is extremely feeble, a defect or broken wire is
suspected, ask your Komatsu distributor for possible repairs.
1. Turn the starting switch to the ON position.
2. Press the horn switch at the front of the left armrest and check
that the horn sounds.

CHECK ELECTRIC WIRING

CAUTION
If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu
distributor to locate the cause and make the repair.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash
the battery cap to clear the breather hole.

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

CHECK THAT LAMPS LIGHT UP

Check that the head lamps, rear working lamp, and lighting inside the instrument panel light up properly. Check also
that there is no dirt or damage.
If any lamp does not light up, the bulb is probably blown or there is a disconnection, so contact your Komatsu
distributor for repairs.
1. Turn the starting switch to the ON position.
2. Turn the lamp switch to the OFF, 1, and 2 positions, and check
that the lamps light up and go out.

3 - 26
.

OPERATION OPERATION

CHECK BACKUP ALARM SOUND

(If equipped)
Check that the backup alarm sounds normally. If it does not, a defect or broken wire is suspected, ask your Komatsu
distributor for possible repairs.
1. Turn the starting switch to the ON position.
2. Set the safety lock lever (for the steering, directional and gear
shift lever) to the FREE position (F).

3. Set the steering, directional and gear shift lever in the

REVERSE position.
The alarm must sound immediately at this time. The alarm
keeps sounding until the steering, directional and gear shift
lever is set to the NEUTRAL or FORWARD position.

3 - 27
.

OPERATION OPERATION

ADJUSTMENT

ADJUST OPERATOR'S SEAT

WARNING
When adjusting the position of the operator's seat, always set the safety lock lever to the LOCK position to prevent any accidental
contact to the control levers.

Always adjust the operator's seat before starting each operation or when the operators change shift.
When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can
be fully depressed.

FORE-SFT ADJUSTMENT OF SEAT

Move the lever (1) to the right, set the seat to the desired position,
then release the lever.

Fore-aft adjustment: 160 mm (6.3 in) (9 stages)

FASTENING AND REMOVING SEAT BELT

WARNING
Before fitting the seat belt, check that there is no abnormality in the mounting bracket and mounting belt of the belt. If the belt
is worn or damaged, replace it.
Replace the seat belt every three years, even if their outside is free from abnormality. The year of manufacture is woven on the
back side of the belt.
Always fasten the seat belt before starting operations.
Always use the seat belt during operations.
Do not twist the left or right side of the seat belt when fastening it.

Check that the bolts of the clamp securing the belt to the chassis are not loose. Tighten them if they are loose.
The tightening torque for the mounting bolt is 24.5 ± 4.9 N·m (2.5 ± 0.5 kgf·m, 18.1 ± 3.6 lbft).
If the belt surface is scratched or frayed or if the fittings are broken or deformed, replace the seat belt unit.

3 - 28
.

OPERATION OPERATION

FASTENING AND REMOVING SEAT BELT

1. After adjusting the seat poaition, sit in the seat. Grip buckle (1)
and tongue (2) in each hand and insert tongue (2) into buckle
(1). Confirm by pulling the belt that the tongue is securely
locked to the buckle.
2. When removing the belt, raise the tip of buckle (1) 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.

SEAT BELT ADJUSTMENT

SHORTENING
Pull the free end of the belt on either the buckle body or tongue
side.

LENGTHENING
Pull the belt while holding it at a right angle to the buckle or tongue.

3 - 29
.

OPERATION OPERATION

OPERATION AND CHECK BEFORE STARTING ENGINE

WARNING
When starting the engine, check that the safety lock lever are placed securely at the LOCK position. If the work equipment control
lever is touched by accident when the engine is started, the work equipment may move unexpectedly and cause serious injury or
damage.

1. Check that the brake pedal is locked by brake lock lever (1).

2. Check that 1 (1st) is displayed in speed range display window

(2).
If 1 (1st) is not displayed, operate steering, directional and gear
shift lever (3) to 1 (1st).

3 - 30
.

OPERATION OPERATION

3. Check that safety lock lever (for the steering, directional and
gear shift lever) (4) and the safety lock lever (for the blade
control lever) (5) are at LOCK position (L).

REMARK
If the safety lock lever (for the steering, directional and gear shift
lever) is not at LOCK position (L) , the engine will not start.

3 - 31
.

OPERATION OPERATION

STARTING ENGINE

NORMAL STARTING
WARNING
Start the engine only after sitting down in the operator's seat.
Do not attempt to start the engine by short-circuiting the engine starting
circuit. Such an act may cause serious bodily injury or fire.
Check that there are no persons or obstacles in the surrounding area,
then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be
particularly careful to ensure good ventilation.

NOTICE
Do not keep the starting motor rotating continuously for more than 20 seconds.
If the engine will not start, wait for at least 2 minutes before trying to start the engine again.

1. Before starting the engine, check that fuel control lever (1) is at the low idling position.
2. Pull fuel control lever (1) slightly from the low idling position.

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

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

3 - 32
.

OPERATION OPERATION

STARTING IN COLD WEATHER

WARNING
Start the engine only after sitting down in the operator's seat.
Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury
or fire.
Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Never sue starting aid fluids as they may cause explosions.
Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.

NOTICE
Do not keep the starter motor running for more than 20 seconds
continuously.
If the engine does not start, wait for about 30 seconds and begin with the
step 3. again.

When starting in low temperatures, do as follows.

1. Before starting the engine, check that fuel control lever (1) is at the low idling position.
2. Pull fuel control lever (1) to a position midway between the low
idling and full speed positions.

3. Hold the key in starting switch (2) at HEAT position (D) to carry
out preheating.

The preheating time is as shown in on the right.

Ambient temperature Preheat time
If the preheating time is too long or too short, the engine will not
start easily. Observe the correct preheating time. Above 0°C -
0°C to -10°C 10 seconds
-10°C to -20°C 15 seconds

3 - 33
.

OPERATION OPERATION

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

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

3 - 34
.

OPERATION OPERATION

OPERATIONS AND CHECKS AFTER STARTING ENGINE

WARNING
If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position.
If the work equipment is operated without warming the machine up sufficiently, the response of the work equipment to the
movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always carry out
the warming-up operation. Particularly in cold areas, be sure to carry out the warming-up operation fully.

BREAKING IN THE NEW MACHINE

CAUTION
Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe
conditions at the beginning can adversely affect the performance and shorten the machine life.
Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
During breaking-in operations, follow the precautions described in this manual.

Idle the engine for 5 minutes after starting it up.

Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and
sudden changes in direction.

3 - 35
.

OPERATION OPERATION

WARMING UP OPERATIONS
After starting the engine, do not immediately start operations. First, carry out the following operations and checks.

NOTICE
Avoid abrupt acceleration until warm-up run is completed.
Do not run the engine at low idling or high idling for more than 20 minutes.
If it is necessary to run the engine at idling, apply a load or run at a medium
speed from time to time.

1. Pull fuel control lever (1) to the center position between LOW
IDLING and HIGH IDLING and run the engine at medium
speed for about 5 minutes with no load.

2. In cold weather only, operate steering, directional and gear

shift lever (2) as follows.
Operate steering, directional and gear shift lever (2) from the N
position fully to the left and hold it for 5 seconds. Next, operate
it fully to the right and hold it for 5 seconds.
Repeat this operation in each direction in turn for approx. 5
minutes with the engine running under no load.

3. After carrying out the warming-up operation, check that the

gauges and caution lamps work normally. If any abnormality
is found, carry out maintenance and repair.
Run the engine under no load until the indicator of engine water
temperature gauge (3) is in the green range.
4. Check that there is no abnormal exhaust gas color, noise or
vibration. If any abnormality is found, contact your Komatsu
distributor.

3 - 36
.

OPERATION OPERATION

STOPPING ENGINE

NOTICE
If the engine is stopped abruptly, service life of component parts of the
engine may be considerably reduced. Hence do not stop the engine
abruptly except in an emergency. If the engine has overheated, do not try
to stop it abruptly but run it at medium speed to allow it to cool down
gradually, and then stop it.

1. Run the engine at low idling for about 5 minutes to cool down gradually.
2. Turn the key in starting switch (1) to the OFF position (A) and
stop the engine.

3. Remove the key from starting switch (1).

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.

OPERATION OPERATION

MACHINE OPERATION

MOVING MACHINE OFF

WARNING
When starting the machine off, check that the area around the machine is safe and sound the horn before moving.
Clear all personnel from the area around the machine.
Be particularly careful when traveling in reverse. The area to the rear of the machine is a blind spot.
When moving the machine off up a steep slope, place the steering, directional and gear shift lever in 1st, pull the fuel control
lever fully, and run the engine at full speed.

1. Set safety lock lever (for the blade control lever) (1) to the
FREE position (F).

3 - 38
.

OPERATION OPERATION

2. Put blade control lever (2) in the RAISE position to raise the
blade 40 to 50 cm (15.8 to 19.7 in) off the ground.

3. Depress brake pedal (3), push brake lock lever (4) and set it to
the FREE position (F).

4. Depress inching pedal (5) fully.

5. Set safety lock lever (for the steering, directional and gear shift
lever) (6) to the FREE position (F).

6. Operate steering, directional and gear shift lever (7), and check
that the desired speed range is displayed in the speed range
display window (8).
1: 1st
2: 2nd
3: 3rd (If equipped)

3 - 39
.

OPERATION OPERATION

7. Move steering, direction and gear shift lever (7) to the F

(forward) or R (reverse) position to move the machine off.

REMARK
For machines equipped with a back-up alarm, check that the alarm
sounds when the steering, directional and gear shift lever is placed
in REVERSE. If the alarm does not sound, ask your Komatsu
distributor to carry out repairs.

8. Let inching pedal (5) back slowly and allow the machine to
move off.

9. Pull fuel control lever (9) and raise the engine speed.

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.

OPERATION OPERATION

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

1. Set fuel control lever (1) to low idling position (A) and lower the
engine speed.

2. Depress inching pedal (2) fully, then depress brake pedal (3) to
stop the machine.

3. Set steering, directional and gear shift lever (4) to the N

position.

3 - 41
.

OPERATION OPERATION

SHIFTING GEAR
The machine does not have to be stopped to shift gears.

1. Move joystick (1) to the desired gear position to shift gears.

1: 1st
2: 2nd
3: 3rd (If equipped)

Check the speed range in speed range display window (2).

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.

OPERATION OPERATION

SHIFTING BETWEEN FORWARD AND REVERSE

CAUTION
When shifting between forward and reverse, reduce speed to reduce the
shock and ensure safety.
It is possible to shift between forward and reverse without stopping the
machine, but to ensure safety and operator comfort and to extend the
service life of the transmission system, do not shift when the engine is
running at full speed. Lower the engine speed, stop the machine, then
switch between forward and reverse.

1. Depress inching pedal (1) fully, then depress brake pedal (2) to
stop the machine.

2. Shift steering, directional and gear shift lever (2) to the desired
position.
Position (F): Forward
Position (N): Neutral
Position (R): Reverse

REMARK
For machines equipped with a back-up alarm, check that the alarm
sounds when the steering, directional and gear shift lever is placed
in REVERSE. If the alarm does not sound, ask your Komatsu
distributor to carry out repairs.

3. Release brake pedal (2), then let inching pedal (1) back slowly
and allow the machine to move off.

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.

OPERATION OPERATION

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

To turn the machine while traveling, incline joystick (1) in the

direction to turn.

NORMAL TURNING

WHEN TURNING TO THE LEFT GRADUALLY WHILE TRAVELING FORWARD

When steering, directional and gear shift lever (1) is at the
FORWARD position (F) and it is operated partially to the left (L), the
steering clutch is disengaged and the machine turns gradually to
the left.

REMARK
When steering, directional and gear shift lever (1) is at the
FORWARD position (F) and it is operated partially to the right (R),
the steering clutch is disengaged and the machine turns gradually
to the right.
Do the same to turn gradually while traveling in reverse.

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.

OPERATION OPERATION

WHEN MAKING A PIVOT TURN TO THE LEFT WHILE TRAVELING

When steering, directional and gear shift lever (1) is at the
FORWARD position (F) and it is operated fully to the left (L), the
steering clutch is disengaged, the steering brake is applied, and
the machine makes a pivot turn to the left.

REMARK
When steering, directional and gear shift lever (1) is at the
FORWARD position (F) and it is operated fully to the right (R), the
steering clutch is disengaged, the steering brake is applied, and
the machine makes a pivot turn to the right.
Do the same to make a pivot turn while traveling in reverse.

3 - 45
.

OPERATION OPERATION

TURNING WHILE DESCENDING A SLOPE

WARNING
Run the engine at low speed.
In addition, when moving very small distances, use the inching panel.
When traveling on slopes, the brake can be used even when the inching panel is being depressed, but always depress the brake
with your right foot and take care to prevent the machine from falling.

REMARK
Cross steering means the phenomenon that the machine turns in the opposite direction to the actual steering
direction.

WHEN TURNING TO THE LEFT GRADUALLY WHILE TRAVELING FORWARD

When steering, directional and gear shift lever (1) is at the
FORWARD position (F) and it is operated partially to the right (R),
the machine turns gradually to the left (Cross steering).

REMARK
When steering, directional and gear shift lever (1) is at the
FORWARD position (F) and it is operated partially to the left (L), the
machine turns gradually to the right (Cross steering).
Do the same to turn gradually while traveling in reverse.

3 - 46
.

OPERATION OPERATION

WHEN TURNING TO THE LEFT SHARPLY WHILE TRAVELING FORWARD

When steering, directional and gear shift lever (1) is at the
FORWARD position (F) and it is operated fully to the left (L), the
machine makes a sharp turn to the left. (The machine does not
turn in the opposite direction.)

REMARK
When steering, directional and gear shift lever (1) is at the
FORWARD position (F) and it is operated fully to the right (R), the
machine makes a sharp turn to the right. (The machine does not
turn in the opposite direction.)
Do the same to make a sharp turn while traveling in reverse.

USING THE LEVER GUIDE FOR FINE CONTROL

If you use the lever guide, it is easier to make fine adjustments of
the steering direction.
There are the following two methods of using the lever guide.
A: Hook your fingers or thumb lightly over the left or right guide, and
operate the steering with a light touch.
B: Keep your wrist fixed and run your fingers along the front of the
guide to operate the steering.
Select the method of operation that is best for you to match the
frequency and ease of operating the steering.

3 - 47
.

OPERATION OPERATION

PRECAUTIONS FOR OPERATION

METHOD OF USING STEERING CLUTCH

If the steering clutch on one side is operated frequently, or slow turns are made with the clutch partially engaged,
the steering clutch will wear more quickly, so arrange the travel path and steering operations suitably.

PERMISSIBLE WATER DEPTH

When operating in water, always keep the bottom of carrier roller
(1) above the surface of the water. Also, be careful that the engine
cooling fan will not come in contact with water. The fan can be
damaged.

PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS

USE ENGINE AS BRAKE

When traveling downhill, set the steering, directional and gear shift lever in a low speed range, run the engine at low
speed, and use the engine as a brake.
Never coast downhill with the steering, directional and gear shift lever at the N position or with the inching pedal
depressed.

BRAKING WHEN TRAVELING DOWNHILL

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

PRECAUTIONS ON SLOPES

BE CAREFUL OF FUEL LEVEL

If the fuel level in the fuel tank becomes low when working on slopes, the engine may suck in air because of the angle
of the machine or the swaying of the machine. 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 when the machine is traveling or carrying out operations on a slope, immediately depress the
brake pedal and lower the work equipment to the ground to stop the machine, then pull the brake lock lever to lock
the brake pedal.
After stopping the machine, return the steering, directional and gear shift lever to the N position, then start the engine
again.

3 - 48
.

OPERATION OPERATION

WORK POSSIBLE USING BULLDOZER

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

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

When dozing toward one side only, operate with angled blade
(angledozer only).

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

To finish the ground to a flat surface after digging or leveling, put a

full load of soil in front of the blade and operate the blade up and
down in small movements while traveling forward. Finally, place
the blade at FLOAT and travel at low speed in reverse while pulling
the blade over the ground surface. Before doing this, hold the lever
by hand at the FLOAT position for at least 1 second to make sure
that it stays in position. To prevent damage to the blade, be careful
not to travel over any stones or rocks.

3 - 49
.

OPERATION OPERATION

CUTTING INTO HARD OR FROZEN GROUND OR DITCHING

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

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.

3 - 50
.

OPERATION OPERATION

PARKING MACHINE
WARNING
Park the machine on firm, level ground.
Avoid parking the machine on a slope.
If the machine has to be parked on a slope, apply the brake and lock it
with the brake lock lever, put blocks under the track, then dig the work
equipment into the ground to prevent the machine from moving.
If the control lever is touched by mistake, the work equipment or
machine may move suddenly and cause a serious accident. Before
standing up from the operator's seat, always set the safety lock lever
securely to the LOCK position.

1. Stop the machine. For details, see "STOPPING MACHINE (PAGE 3-41)".
2. Depress brake pedal (1) strongly.
Keep the brake pedal depressed and pull brake lock lever (2)
to LOCK position (L) to lock the brake pedal.

3. Set the safety lock lever (for the steering, directional and gear
shift lever) (3) to the FREE position (F).

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.

OPERATION OPERATION

4. Operate balde control lever (4) to the LOWER position, and

lower the blade to the ground.

5. Set safety lock lever (for the blade control lever) (5) to the
LOCK position (F).

3 - 52
.

OPERATION OPERATION

CHECK AFTER FINISHING WORK

BEFORE STARTING ENGINE

Use the meters and lamps to check the engine water temperature,
engine oil pressure, remaining fuel level, and air cleaner clogging.

AFTER STARTING ENGINE

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

LOCKING
To prevent vandalism, there are locks at the following places.
Places that can be locked with the starting switch key.
(1) Cover on top of engine hood
(2) Cover on side of hydraulic tank
(3) Inspection window in right engine side cover

Commercially available locks can be fitted to the following places.

(4) Battery inspection cover

3 - 53
.

OPERATION OPERATION

TIPS FOR LONGER UNDERCARRIAGE LIFE

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

OPERATION METHOD
Select the track shoe that best suits the type of soil to be encountered in service.
Please consult your Komatsu distributor when selecting track shoes.
Do not allow shoe slipping to occur during operation.
If shoe slipping occurs, reduce load to the blade until slipping stops.
Avoid sudden starts, acceleration or stops, unnecessarily high speeds and sharp turns.
Always operate machine in a straight line whenever possible. When making turns, be careful not to allow the
machine to stay to one side, so operation in both turning directions can be done properly. Make turns with the
largest possible radius.
Prior to operation, clear boulders and obstacles to prevent machine from riding over them while operating.
On a slope, operate the machine parallel to the inclination of the
slope. Do not operate across the slope. Also when stopping the
machine on a slope, the machine should face toward the top of
the slope.
When ground inclines to left or right during digging 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
obstacles that resist the power of the machine during dozing
operations.

INSPECTION AND ADJUSTMENT

Properly adjust the track tension.
The tension should be measured at clearance (A) between the
idler and carrier roller shown in the right diagram - usually 20 to
30 mm (0.8 to 1.2 in) at this point. For rocky terrain, tighten the
tracks slightly. In clay or sandy areas, loosen them slightly. (For
inspection and adjustment procedures, refer to "CHECK AND
ADJUST STEEL SHOE TENSION (PAGE 4-23)".)
Check idler rollers for oil leakage as well as for loose bolts and
nuts. If any trouble is detected, repair immediately.

Check clearance (B) between the idler guide plate and track
frame. If clearance (B) increases, idler may move sideways and
the tracks may come off. (For inspection and adjustment
procedure, refer to "ADJUST IDLER CLEARANCE (PAGE
4-37)".)

3 - 54
.

OPERATION OPERATION

INSPECTION AND REPAIR

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

MEASURING LINK PITCH

1. Insert a wooden block between track shoe and sprocket to take
up the slack in track shoes.

2. Measure the pitch length (L) of 4 links at a straight portion at

least 2 links from master pin (A). Divide this measurement by
four to obtain the link pitch.
Standard link pitch (P): 135 mm (5.3 in)
Link pitch limit for turning bushing: 138 mm (5.4 in)
There is a center hole in both ends of the master pin.

REMARK
The measured value under decimal of Link pitch is different from
the basic value depend upon the precision of measure or the
tolerance of product even if it isn't worn out.
Don't judge it's worn out soon, do it with the trend of measured
value after that.

MEASURING HEIGHT OF GROUSER

Remove any slack in the track shoe and measure the height of the
grouser at the center of the shoe.
Standard dimension (h): 38.5 mm (1.5 in)
Repair limit: 15 mm (0.6 in)

3 - 55
.

OPERATION OPERATION

MEASURING OUTSIDE DIAMETER OF TRACK ROLLER

1. Measure the height (dimension C) of the link tread as shown in
the diagram.
2. Stop the machine at a point where the link tread (for which
dimension C was measured) is completely in contact with the
roller tread, then measure dimension B.
3. Calculate the outside dimension of the tread (dimension A).
A = (B - C) x 2
Standard dimension (A): 135 mm (5.3 in)
Repair limit: 127 mm (5.0 in)

3 - 56
.

OPERATION OPERATION

HANDLING RUBBER SHOES (RUBBER SHOES ONLY)

SKILLFUL USE OF RUBBER SHOES

Rubber shoes have various excellent properties that are not found in steel shoes. However, if rubber shoes are
used in the same way as steel shoes, they cannot make full use of these qualities.
Carry out operations within the capacity of the rubber shoes in a way that matches the nature of the work and the
conditions of the jobsite.

COMPARISON OF RUBBER SHOES AND METAL SHOES

Rubber shoes Steel shoes
Little vibration w ∆
Smooth travel w {
Little noise w ∆
No damage to paved surface w ∆
Easy to handle w ∆
Easily damaged ∆ w
Storong drawber pull w w
w: Excellent
{: Good
∆: Average
Rubber shoes offer various advantages provided by the properties of the material. At the same time, the weak point
is their lack of strength. Therefore, it is important to understand the properties of rubber shoes and to follow the
various precautions regarding handling and prohibited work. This will extend the service life of the rubber shoes and
allow the machine to demonstrate the advantages of the rubber shoes.
Before using rubber shoes, always read "PRECAUTIONS WHEN USING RUBBER SHOES (PAGE 3-58)".

WARRANTY FOR RUBBER SHOES

It is important to inspect and maintain the tracks at the correct tension. Furthermore, these shoes must not be used
near objects where they are likely to suffer damage, such as the corners of steel plates, U-shaped ditch liners,
blocks, on crushed rock or the sharp edges of rocks, iron beams, or scrap iron.
Any damage resulting from the customer's mistaken use of the machine shall not be included in the scope of the
warranty.

3 - 57
.

OPERATION OPERATION

PRECAUTIONS WHEN USING RUBBER SHOES

PROHIBITED WORK
Do not carry out the following types of work.
Carrying out operations and steering on crushed rock, extremely rough hard rock, steel beams, scrap iron, or near
the edges of steel plates will cause damage to the rubber shoes.
In places such as riverbeds where there are large numbers of
large and small boulders and stones, the stones may get caught
and damage the rubber shoes or cause the track to come off. If
the machine continues to be used for dozing operations when
the shoes are slipping, the service life of the rubber shoes will be
reduced.

Be careful not to get oil, fuel, or chemical solvent on the rubber

shoes. If such a substance should get on the shoes, remove it
immediately. Furthermore, do not travel on road surfaces where
oil has collected.

When putting the machine into long-term storage (3 months or more), store the machine indoors where it is
protected from direct sunlight or rain.
Do not use the machine in high-temperature areas, such as
areas where there is burning wood, steel plates that have been
left under the hot sun, or places where asphalt has been laid.

3 - 58
.

OPERATION OPERATION

PRECAUTIONS WHEN USING

Be careful of the following points when carrying out work.
Avoid making sudden turns on concrete road surfaces. This may leave rubber remains on the road surface.
Avoid making sudden changes in direction. This may cause premature wear or damage to the rubber shoes.
Avoid operating the steering when traveling over places where
there is a big difference in height. When traveling over obstacles
or places where there is a difference in height, drive the machine
at right angles to the obstacle to prevent the shoes from coming
off.
When using the blade to jack up the machine, be careful to lower
the machine slowly.
Avoid doing work with materials that produce oil when crushed
(soya beans, corn, or remains of vegetables squeezed for oil);
or wash the machine after use.
Avoid handling materials that will attack the adhesion of the
steel core, such as salt, ammonium sulphate, potassium
chloride, potassium sulphate, or calcium superphosphate; or
wash the machine after use.
The adhesion of the core will be attacked by salt, so avoid using
the machine in coastal areas.
When handling salt, sugar, wheat, or soya beans, if there is any
deep cut in the rubber shoes, these substances may get into the
lugs or cut portion of the rubber. Always repair the rubber before
use.
Do not carry out work that involves scraping against walls or
concrete embankments.
Rubber shoes slip extremely easily on snow or frozen roads. Be
careful not to slip when traveling or working on slopes.
The properties of rubber shoes change when working in extermely cold places, and this will reduce the life of the
rubber shoe.
Because of the properties of rubber, use the rubber shoes within a range of -25°C to +55°C (-13°F to +131°F).

Always maintain the rubber shoes at the proper tension to prevent them from coming off.
If the tension is low, the rubber shoes will come off under the following conditions.
Even if the tension is correct, be extremely careful when carrying out operations.
1. Avoid operating the steering when traveling over curbs, rocks,
or places where there is a big difference in height (more than
approx. 20cm (8 in)). When traveling over such objects, always
travel at right angles to the object.

3 - 59
.

OPERATION OPERATION

2. When traveling in reverse up a slope, do not turn when moving

from flat ground onto the slope.
If it is necessary to turn on slopes, be sure to turn gradually.

3. Avoid traveling along the edge of a slope or on rough ground

with the track on one side raised (with the machine tilting at
angle of more than approx. 10°), and one side on the flat
ground.
To avoid damage to the rubber shoes, travel with both tracks
on flat ground.

4. If the machine is operated as explained in 1 to 3 above, the

rubber shoes is slackened. Do not steer the machine in the
positions shown in the figure.

(Mechanism of rubber shoe coming off track)

1) When the track goes over an obstacle, a gap forms
between track roller (A) and rubber shoe (B). In this
condition, the rubber shoes may come off.

3 - 60
.

OPERATION OPERATION

2) If the machine travels further in reverse, a gap is formed

between track roller (A), idler (C) and rubber shoe (B).

When turning in a condition where the rubber shoe cannot move

to the side because of the object it is passing over, or because
of some other object.
(D): Rubber shoe side
(E): Frame side

When the rubber shoe has moved out of alignment and the idler or track roller are not aligned with the core.
If the machine travels in reverse in this condition, the rubber
shoe will come off.

If the machine is turned in this condition, the rubber shoe will

come off.

3 - 61
.

TRANSPORTATION OPERATION

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

TRANSPORTATION MEANS
As a rule, transport the machine on a trailer, as a rule.
Select a trailer according to the mass and dimensions of the machine shown in "SPECIFICATIONS (PAGE 5-2)".
Note that the mass and dimensions for transportation shown in SPECIFICATIONS depend on the types of shoe,
blade, etc.

LOADING, UNLOADING WORK

WARNING
Since loading and unloading of the machine is dangerous, be extremely careful.
When loading or unloading the machine, operate it slowly with the engine speed low and the transmission in the 1st gear.
Use ramps having sufficient width, length, thickness, and strength. Install them securely and set their angle to 15° or less.
If the ramps are deflected appreciably, reinforce them with blocks.
Perform the loading work of the machine on firm, level ground. Secure sufficient distance between the shoulder of the road and
the trailer.
Remove mud from the undercarriage of the machine so that the machine will not slip sideways on the ramps. In addition,
remove water, snow, ice, grease, oil, etc. from the ramps.
Never steer the machine on the ramps, since steering on the ramps can cause the machine to tip over. If it is necessary to
change the travel direction, return to the ground or to the bed of the trailer, then change the travel direction.
The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and the machine is
unbalanced and becomes dangerous. Accordingly, pass the border slowly.

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

LOADING WORK
1. Load and unload on firm level ground only.
Maintain a safe distance from the edge of a road.
2. Apply the trailer brakes securely and put blocks (1) under the
tires to hold the trailer in position.
Set gap (3) between ramps (2) to match the width of the track,
and keep angle (4) to a maximum of 15°.
If ramps (2) bend appreciably under the weight of the machine,
put wooden block (5) under the ramps to support them.

3. Run the engine at low speed.

In addition, when moving very small distances, use the inching panel.
When traveling on slopes, the brake can be used even when the inching panel is being depressed, but always
depress the brake with your right foot and take care to prevent the machine from falling.
4. The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and the
machine is unbalanced and becomes dangerous. Accordingly, pass the boarder slowly.
5. Load the machine correctly in the specified position on the trailer.

3 - 62
.

OPERATION TRANSPORTATION

SECURING MACHINE

WARNING
When the edge of the blade protrudes beyond the trailer, angle the blade.

After placing the machine on the specified position of the trailer, secure it according to the following procedure.
1. Lower the work equipment slowly.
2. Set the safety lock lever to the LOCK position (L).

3. Depress the brake pedal, then pull the brake lock lever to the
LOCK position (L) to lock the brakes.

4. Move the fuel control lever to the low idling position, turn the
starting switch to the OFF position, and stop the engine.
Remove the key from the starting switch.

5. Fix the machine as explained below so that it will not move

during transportation.
In particular, fix the machine securely to prevent it from slipping
sideways.
1) Put blocks (1) in front and behind the track shoes of both
sides.
2) Set up chain or wire, following (A) or (B).
A: Set up chain or wire around the track shoes.
B: Set up chain or wire through the holes of track links.
3) Protect the wire from contacting directly with angular parts
of the machine, by inserting pads.

3 - 63
.

TRANSPORTATION OPERATION

UNLOADING WORK
1. Load and unload on firm level ground only.
Maintain a safe distance from the edge of a road.
2. Apply the trailer brakes securely and put blocks (1) under the
tires to hold the trailer in position.
Set gap (3) between ramps (2) to match the width of the track,
and keep angle (4) to a maximum of 15°.
If ramps (2) bend appreciably under the weight of the machine,
put wooden block (5) under the ramps to support them.

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

4. Start the engine.
Warm the engine up fully.
5. Depress the brake pedal, then push the brake lock lever to the
FREE position (F).

6. Set the safety lock lever to the FREE position.

7. Run the engine at low speed.

In addition, when moving very small distances, use the inching panel.
When traveling on slopes, the brake can be used even when the inching panel is being depressed, but always
depress the brake with your right foot and take care to prevent the machine from falling.
8. Raise the blade.
9. Set the travel direction toward the ramps and drive slowly.
10. The center of gravity of the machine shifts suddenly at the border between the ramps and trailer, and the
machine is unbalanced and becomes dangerous. Accordingly, pass the boarder slowly.
11. Drive down the ramps slowly and carefully until the machine leaves the ramps perfectly.

3 - 64
.

OPERATION TRANSPORTATION

LIFTING MACHINE
WARNING
Do not lift the machine with any worker on it.
Use wire ropes having sufficient strength for the weight of the machine.
Lift the machine only in the position shown below. If it is lifted in another position, it may be unbalanced.
Lift the machine horizontally.

NOTICE
The lifting procedure applies to machines with standard specifications.
The method of lifting differs according to the attachments and options actually installed. In such cases, please contact your
Komatsu distributor for information.

For details of the weight, see "SPECIFICATIONS (PAGE 5-2)".

PROSEDURE FOR LIFTING OPERATIONS

When lifting the machine, stop it on a level place, then observe the following procedure.
1. Stop the engine, depress the brake pedal fully, then pull the brake lock lever to lock the brake pedal.
2. Use wire rope, sling, or other lifting equipment according to the
weight, pass the wire rope around lifting positions (A), then fit
it to the lifting equipment.

NOTICE
Use protectors, etc. so that the wire ropes will not be broken at sharp
edges or narrow places.
Use spreaders and bars having sufficient width so that they will not
touch the machine.

3. After setting the wire ropes, lift up the machine and stop at 100
to 200 mm (3.9 to 7.9 in) above the ground, and check that the
wire ropes are not slack and the machine is horizontal, then lift
up slowly.

Lifting mark

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COLD WEATHER OPERATION OPERATION

COLD WEATHER OPERATION

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

FUEL AND LUBRACANTS

Change the fuel and oil for each component to those of lower viscosity. For the specific viscosity, see "USE OF
FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-8)".

COOLANT

WARNING
Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash
it off with large amount of fresh water and see a doctor at once.
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator,
please contact your Komatsu distributor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the
ground surface.
Antifreeze is flammable, so do not bring any flame close. Do not smoke when handling antifreeze.

NOTICE
Never use methanol, ethanol, or propanol-based antifreeze.
Never use any water-leakage prevention agent or any antifreeze containing such an agent.
Do not mix different types of antifreeze.

For details on the amount of antifreeze mixture and on when to change the coolant, see "CLEAN INSIDE OF
COOLING SYSTEM (PAGE 4-20)".
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the
standard requirements 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
SAE J1034
FEDERAL STANDARD O-A-548D

REMARK
In areas where permanent antifreeze is not available, it is possible to use antifreeze whose main component is
ethylene glycol and does not contain any corrosion inhibitor. (Such antifreeze can be used for the winter season
only.) However, in such a case, the cooling water must be changed twice a year (spring and fall), so use permanent
antifreeze when possible.

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OPERATION COLD WEATHER OPERATION

BATTERY

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

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

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

Temperature
(°C) 20 0 -10 -20
Charging
Rate (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26

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.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add the water after
the day's work so as to prevent fluid in the battery from freezing in the night.

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.

COLD WEATHER OPERATION OPERATION

AFTER COMPLETION OF WORK

WARNING
After completion of operations, fill the fuel tank to prevent the formation of water caused by condensation of moisture in the
empty space in the tank when the temperature goes down.

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the
following morning, always observe the following precautions.
Mud and water on the machine body should be completely removed. This is to prevent damage to the seal caused
by mud or dirt getting inside the seal with frozen drops of water.
Park the machine on hard, dry ground.
If this is impossible, park the machine on wooden boards.
The boards help protect the tracks from being frozen in soil and the machine can start next morning.
Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
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.
If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add the water after
the day's work so as to prevent fluid in the battery from freezing in the night.

AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all parts with oil of the viscosity specified.
For details, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
(PAGE 4-8)".
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 soft water.

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.

OPERATION LONG-TERM STORAGE

LONG-TERM STORAGE
BEFORE STORAGE
When keeping in long-term storage (more than one month), store as follows.
Clean and wash all parts, then store the machine indoors. If the machine has to be stored outdoors, select level
ground and cover the machine with a sheet.
Fill the fuel tank to prevent moisture from accumulating.
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.
Set the control levers to the neutral position, place the safety lock lever and brake lock lever at the LOCK position,
and place the fuel control lever at the low idling position.

DURING STORAGE
WARNING
If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors, open the doors and windows
to improve ventilation and prevent gas poisoning.

During storage, always operate the machine 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.
Before operating the work equipment, wipe the grease off of the hydraulic piston rod.
For machines equipped with an air conditioner, run the air conditioner.

AFTER STORAGE
NOTICE
If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu
distributor.

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

3 - 69
.

TROUBLESHOOTING OPERATION

TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
When restarting the machine after running out of fuel, fill with fuel and bleed the air from the fuel system before
starting.
For details of bleeding the air, see "REPLACE FUEL FILTER CARTRIDGE (PAGE 4-46)".

MACHINE TOWING METHOD

WARNING
Be sure to use a wire rope sufficiently strong for the towing weight.
When using the towing hook, be sure to use a shackle.
Set the wire rope horizontally and align it with the track frame.
Tow the machine slowly.

If the machine gets stuck in the mud or a heavy thing needs to be

towed, install a towing wire rope to the draw bar pin.

3 - 70
.

OPERATION TROUBLESHOOTING

IF BATTERY IS DISCHARGED
WARNING
When checking or handling the battery, stop the engine and turn the
starting switch key to the OFF position.
The battery generates hydrogen gas, so there is a hazard 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, immediately wash it
off with a large amount of water. If it gets in your eyes, wash it out with
fresh water and consult a doctor.
When handling batteries, always wear protective goggles and rubber
gloves.
When removing the battery, first disconnect the cable from the ground
(normally the negative (-) terminal). When installing, install the positive
(+) terminal first.
If a tool touches the positive terminal and the chassis, there is danger
that it will cause a spark, so be extremely careful.
If the terminals are loose, there is danger that the defective contact may
generate sparks that will cause an explosion.
When removing or installing the terminals, check which is the positive
(+) terminal and which is the negative (-) terminal.

REMOVE AND INSTALL BATTERY

NOTICE
Secure the battery and check that it does not move. If it moves, secure it
in position again.

When removing, remove the ground wire (normally the negative

(-) terminal) first.
It is extremely dangerous if any tool forms a contact between the
terminal and the chassis. This will cause sparks.
When installing the battery, connect the ground cable last.
When replacing the battery, hold the battery securely in position
with the battery mounting clamps.
Tightening torque of mounting nut: 9.8 to 14 N·m
(1 to 1.5 kgf·m, 7.2 to 10.8 lbft)

3 - 71
.

TROUBLESHOOTING OPERATION

PRECAUTIONS FOR CHARGING BATTERY

If the battery is charged improperly, it may explode. Accordingly,
charge it according to "IF BATTERY IS DISCHARGED (PAGE
3-71)" and the instruction manual attached to the charger, and
observe the following items.
Set the voltage of the charger to match the voltage of the battery
to be charged. If the voltage is not selected correctly, the
charger may overheat and cause an explosion.
Connect the positive (+) charger clip of the charger to the
positive (+) terminal of the battery, then connect the negative (-)
charger clip of the charger to the negative (-) terminal of the
battery. Be sure to fix the clips securely.
Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid charging, set
it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and
explode.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery electrolyte and cause the battery to explode.
Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause
an explosion. Always check the battery electrolyte level periodically and add distilled water to bring the electrolyte
level to the UPPER LEVEL line.

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.

OPERATION TROUBLESHOOTING

STARTING ENGINE WITH BOOSTER CABLE

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

PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE

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

NOTICE
The starting system for this machine uses 12V. For the normal machine, also use a 12V battery.
The size of the booster cable and clip should be suitable for the battry size.
The battry of the normal machine must be the same capacity as that of the engine to be started.
Check the cables and clips for damage or corrosion.
Make sure that the cables and clips are firmly connected.
Check that the safety lock levers and brake lock levers of both machine are in the LOCK position.
Check that each lever is in the NEUTRAL position.

3 - 73
.

TROUBLESHOOTING OPERATION

CONNECTING THE BOOSTER CABLE

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

STARTING ENGINE

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

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

DISCONNECTING THE BOOSTER CABLE

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

3 - 74
.

OPERATION TROUBLESHOOTING

OTHER TROUBLE

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

Problem Main causes Remedy

Lamp dose not glow brightly even Defective wiring ( Check, repair loose terminals,
when the engine runs at high speed disconnections)
Defective adjustment of belt Adjust fan belt tension. For
Lamp flackers while engine is tension details, see EVERY 1000
running HOURS SERVICE
Charge lamp dose not goes out Defective alternator ( Replace)
even when engine is running Defective wiring ( Check, repair)
Abnormal noise is generated from Defective alternator ( Replace)
alternator
Starting motor dose not turn when Defective wiring ( Check, repair)
starting switch is turned to ON Insufficient battery charge Charge
Pinion of starting motor keeps Insufficient battery charge Charge
going in and out
Starting motor turns engine Insufficient battery charge Charge
sluggishly Defective starting motor ( Replace)
Starting motor disengages before Defective wiring ( Check, repair)
engine starts Insufficient battery charge Charge
Oil pressure caution lamp dose not Defective caution lamp ( Replace)
light up when engine is stopped Defective caution lamp switch ( Replace)
(starting switch at ON position)
Charge lamp dose not light up Defective charge lamp ( Replace)
when engine stopped (starting Defective wiring ( Check, repair)
switch at ON position)
Defective wiring ( Check, repair)
Outside of electrical intake air Disconnection in electrical intake ( Replace)
heater is not warm when touched air heater
by hand Defective operation of heater ( Check, repair heater switch)
relay switch

3 - 75
.

TROUBLESHOOTING OPERATION

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

Problem Main causes Remedy

Oil pressure of transmission is
When steering and directional lever not raised
is moved to desired position, Insufficient oil in transmission Add oil to specified level, see
machine does not start,or traveling case CHECK BEFORE STARTING
speed is slow Clogged strainer in transmission Clean strainer
case
Steering clutch of moved side is ( Check,adjust steering clutch)
not disengaged
When steering and directional lever
Steering oil pressure does not
is moved in direction to turn
reach the specified pressure (air
machine, machine does not turn
is leaking into oil pump)
and goes straight
Brake of moved side is not Adjust brake
actuated
When brake pedal is depressed, Brakes out of adjust Adjust track tension, see WHEN
machine dose not stop REQUIRED
Track too loose Adjust track tension, see WHEN
Track comes off
REQUIRED
Track too loose or too tightened Adjust track tension, see WHEN
Abnormal wear of sprocket
REQUIRED
Lack of hydraulic oil Add oil to specified level, see
Blade, rise slowly, dose not rise
EVERY 250 HOURS SERVICE

3 - 76
.

OPERATION TROUBLESHOOTING

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

Problem Main causes Remedy

Engine oil pan oil level is low Add oil to specified level, see
(sucking air) CHECK BEFORE STARTING
Engine oil pressure caution lamp Clogging oil filter cartridge Repalce cartridge, see EVERY
remains alight when engine speed 500 HOURS SERVICE
is raised after comoletion of Defective tightening of oil pipe, ( Check, repair)
warm-up pipe joint, oil leakage from
damaged part
Defective caution lamp ( Replace)
Cooling water level low, water Add cooling water, repair, see
leakage CHECK BEFORE STARTING
Steam is emitted from top part of Loose fan belt Adjust fan belt tension, see
radiator (pressure valve) EVERY 250 HOURS SERVICE
Dirt or scale accumulated in Change cooling water, clean
cooling system inside of cooling system, see
WHEN REQUIRED
Clogging radiator fin or damage Clean and repair, see EVERY
fin 500 HOURS SERVICE
Indicator of water temperature Defective thermostat ( Replace thermostat)
gauge is in red range on right side Loose radiator filler cap (high Tighteninig cap or replace
of gauge altitued operation) packing
Defective water temperature ( Replace water temperature
gauge gauge)
Indicator of water temperature Defective thermostat Replace thermostat
gauge is in white range on left side Defective water temperature Replace water temperature
of gauge gauge gauge
Lack of fuel Add fuel, see CHECK BEFORE
STARTING
Air in fuel system Repair place where air is sucking
Defective fuel injection pump or ( Replace pump or nozzle)
Engine dose not start when starting
nozzle
motor is turned
Starting motor cracks engine see ELECTRICAL SYSTEM
sluggishly
Defective compression
Defective valve clearance ( Adjust valve clearance)
Too mach oil in oil pan Add oil to specified level, see
Exhaust gas is white or blue CHECK BEFORE STARTING
Improper fual Change to specified fual
Exhaust gas occasionally turns Clogging air cleaner element Clean or replace, see WHEN
black REQUIRED
Defective nozzle ( Replace nozzle)
Defective compression Adjust valve clearance
Combustion noise occasionnally Defective nozzle ( Repalce nozzle)
masks breathing sound
Low grede fuel being used Change to specified fuel
Overheating See item "indicator of water
Abnormal noise generated temperature gauge is in red
(combustion or mechanical) range on right side of gauge"
Damage inside muffler ( Repalce muffler)
Excessive valve clearance ( Adjust valve clearance)

3 - 77
.
.

4-1
.

GUIDE TO MAINTENANCE MAINTENANCE

GUIDE TO MAINTENANCE
Do not carry out any inspection and maintenance operation that is not found in this manual.

CHECK SERVICE METER:

Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried
out.

KOMATSU GENUINE REPLACEMENT PARTS:

Use Komatsu genuine parts specified in the Parts Book as replacement parts.

KOMATSU GENUINE OILS:

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient
temperature.

ALWAYS USE CLEAN WASHER FLUID:

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

CLEAN OIL AND GREASE:

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

CHECKING FOREIGN MATERIALS IN DRAINED OIL:

After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If large
quantity of metal particles or foreign materials are found, always report to the person in charge, and carry out
suitable action.

FUEL STRAINER:
Do not remove the strainer from the filler port when adding fuel.

WELDING INSTRUCTIONS:
Turn off the engine starting switch.
Do not apply more than 200V continuously.
Connect grounding cable within 1m (3.3 ft) from the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happen to come between the welding part and grounding point, change the grounding point
to avoid such parts.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.

DO NOT DROP THINGS INSIDE MACHINE:

When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it will cause damage and malfunction of the machine, and will lead
to failure. If you drop anything inside the machine, always remove it immediately.
Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.

4-2
.

MAINTENANCE GUIDE TO MAINTENANCE

DUSTY WORKSITES:
When working at dusty worksites, do as follows:
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.

AVOID MIXING OILS:

If a different type of oil has to be added, drain the old oil and replace all the oil with the new type of oil. Never mix
different kinds of oil.

LOCKING THE INSPECTION COVER:

Lock inspection cover in position securely with the lock bar. If inspection or maintenance is carried out with the
inspection cover not locked in position, there is a hazard that it may be suddenly blown shut by the wind and cause
injury to the worker.

HYDRAULIC SYSTEM-AIR BLEEDING:

After repairing or replacing hydraulic equipment or after removing the hydraulic piping, it is necessary to bleed the
air from the circuit. For details, see "BLEED AIR FROM HEAD END OF ANGLE CIRCUIT (PAGE 4-34)".

PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES:

When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and
replace with new parts.
When doing this, be careful not to forget to assemble the O-rings and gaskets.
When installing the hoses, do not twist them or bend them into loops with a small radius.
This will cause damage to the hose and markedly reduce its service life.

CHECK AFTER INSPECTION AND MAINTENANCE WORKS:

If you forget carrying out the checks after inspection and maintenance, unexpected problems may occur, and this
may lead to serious injury or property damage. Always do as follows.
Checks after operation (with engine stopped)
Have any inspection and maintenance points been forgotten?
Have all inspection and maintenance items been carried out correctly?
Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped
inside the machine and get caught in the lever linkage mechanism.
Is there any leakage of water or oil? Have all the bolts been tightened?
Checks when engine is running
For the checks when the engine is running, see "TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS
RUNNING (PAGE 2-28)" in the SAFETY section, and take care of safety sufficiently.
Check that the inspected and maintained parts work normally.
Raise the engine speed and check for fuel leakage and oil leakage.

4-3
.

OUTLINE OF SERVICE MAINTENANCE

OUTLINE OF SERVICE
OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with the use.
Always use oil that matches the grade and maximum and minimum ambient temperatures recommended in the
Operation and Maintenance Manual. Even if the oil is not dirty, always change the oil 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 machines are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
please contact your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.

FUEL
After completing the day's operations, fill the fuel tank to force out any air containing moisture. This will prevent
the moisture from condensing and mixing with the 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 (5
°F)). It is necessary to use the fuel that is suitable for the temperature.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from
the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

COOLANT
River water contains large amount 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 antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
This antifreeze is also effective in preventing corrosion on the parts of the engine cooling system. It may be
continuously used for two years or 4000 hours of operation, therefore it may be used throughout the year.
Antifreeze is flammable, so be extremely careful not to expose it to flame or fire.
The proper mixing proportion of the antifreeze depends on the ambient temperature. For the mixing proportion,
see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-20)".
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.

4-4
.

MAINTENANCE OUTLINE OF SERVICE

GREASE
Grease is used to prevent twisting and noise at the joints.
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 long time, add grease.
Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause
wear of the rotating parts.

CARRYING OUT KOWA (Komatsu Oil Wear Analysis)

The oil clinic samples the oil periodically and analyzes it. This is a preventive maintenance service, which provides
early discovery of abnormal parts and wear of the drive parts of the machine. This then makes it possible to ensure
prevention of failures and reduction in downtime.
Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine
the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair
methods.
The oil clinic charges the customer only the actual costs, and provides an immediate report of the results of the
analysis and recommendations for action to take. This low-cost service can save you high costs and inconvenience
in the future, so we strongly recommend you to avail yourself of this service.

KOWA ANALYSIS ITEMS

Analysis of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to
measure the density of metal wear particles in the oil.

Measurement of particle quantity

This uses a PQI (Particle Quantifier Index) measurer to
measure the quantity of large iron particles in the oil.

Others
Measurements are made of items such as the ratio of water or fuel in the oil, and the dynamic viscosity.

4-5
.

OUTLINE OF SERVICE MAINTENANCE

OIL SAMPLING
Sampling interval
250 hours: Engine
500 hours: Other components
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Carry out sampling regularly at fixed intervals.
Do not carry out sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.

STORING OIL AND FUEL

Keep indoors to prevent any water, dirt, or other impurities from getting in.
When keeping drum cans for a long period, put the drum on its side so that the filler port of the 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.
To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use the
oldest oil or fuel first).

FILTERS
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
When replacing oil filters, check if any metal particles are affixed to the old filter. If any metal particles are found,
please contact your Komatsu distributor.
Do not open packs of spare filters until just before they are to be used.
Always use Komatsu genuine filters.

RELATING TO ELECTRIC SYSTEM

It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This
will cause an electrical short circuit and may lead to malfunction of the machine. Do not wash the inside of the
operator's cab with water. When washing the machine, be careful not to let water get into the electrical
components.
Service relating to the electric system is checking fan belt tension, checking damage or wear in the fan belt and
checking battery fluid level.
Never install any electric components other than those specified by Komatsu.
When working at the seashore, carefully clean the electric system to prevent corrosion.

4-6
.

MAINTENANCE WEAR PARTS LIST

WEAR PARTS LIST

Replace wear parts such as the filter element or air cleaner element at the time of periodic maintenance or before
they reach the wear limit. The wear parts should be replaced correctly in order to ensure more economic use of the
machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check the latest part number when ordering parts.

WEAR PARTS LIST

The parts in parentheses are to be replaced at the same time.

Item Part No. Part name Q'ty Replacement frequenty

Engine oil filter YM129150-35151 Cartridge 1 Every 500 hours service
Fuel filter YM119802-55800 Cartridge 1 Every 500 hours service
Hydraulic oil filter 113-60-43321 Cartridge 1 Every 1000 hours service
YM119005-12571 Inner element 1
Air cleaner -
YM129062-12560 Outer element 1
104-72-21140 Edge 1
Blade 12F-929-2170 End bit 2
-
(D21A) (02090-10840) (Bolt) (18)
(02290-10813) (Nut) (18)
10G-72-21260 Edge 1
Blade 10G-72-21270 End bit 2
-
(D21P) (02090-10840) (Bolt) (21)
(02290-10813) (Nut) (21)
NOTICE
When handling parts that weigh more than 25 kg (55 lb), remember that they are heavy objects, and take the necessary care.

4-7
.

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO

AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

*1: ASTM D975 No.1

4-8
.

MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

Reservoir Final drive case

Engine Transfer Transmisson (each) Damper Hydraulic Fuel Cooling
oil pan case * case case system tank system
Capacity D21A D21P
Liters 7.3 13 13 6 8 0.9 33 60 10.8
Specified
US gal 1.93 3.43 3.43 1.59 2.11 0.24 8.72 15.85 2.85
Liters 6.6 13 11 6 8 0.9 21 - -
Refill
US gal 1.74 3.43 2.91 1.59 2.11 0.24 5.55 - -

* Including bevel gear case

REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.

When starting the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil
of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C (50°
F) more or less during the day.

Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.

There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add
single grade oil that matches the temperature range in the table.

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

Charge interval of oil in

Fuel suiphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval

4-9
.

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE

Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, one
EO15-40CD season type)
Diesel sigma S
super dieselmulti-
2 AGIP Rotra MP GR MU/EP -
grade
*Sigma turbo
Multi-purpose gear PYKON premium
3 AMOCO *Amoco 300 -
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 pius 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 Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 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
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2
Mobilube GX
13 MOBIL *Delvac super Mobilgease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special

4 - 10
.

MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
Multi-purpose white
*Superme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease
PETROFIN FINA potonic N
15 FINA kappa TD FINA marson EPL2 FINA tamidor
E FINA potonic NE
Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty
Sunoco ultra prestige Sunoco antifreeze
Sunoco GL5
17 SUN - 2EP and summer
gear oil
Sun prestige 742 coolant
*Ursa super plus Multifak EP2 Coda 2055 startex
18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
TM
20 UNION *Guardol MP gear lube LS Unoba EP -
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C

4 - 11
.

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS MAINTENANCE

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

TORQUE LIST
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and
this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was
replaced.

Thread Width Tightening torque

diameter across
Target value Service limit
of bolt flats
(a)(mm) (b)(mm) N·m kgf·m lbft N·m kgf·m lbft

6 10 13.2 1.35 9.8 11.8-14.7 1.2-1.5 8.7-10.8

8 13 31 3.2 23.1 27-34 2.8-3.5 20.3-25.3
10 17 66 6.7 48.5 59-74 6.0-7.5 43.4-54.2
12 19 113 11.5 83.2 98-123 10.0-12.5 72.3-90.4
14 22 172 17.5 126.6 153-190 15.5-19.5 112.1-141

16 24 260 26.5 191.7 235-285 23.5-29.5 170.0-213.4

18 27 360 37 267.6 320-400 33.0-41.0 238.7-296.6
20 30 510 52.3 378.3 455-565 46.5-58.0 336.3-419.5
22 32 688 70.3 508.5 610-765 62.5-78.0 452.1-564.2
24 36 883 90 651 785-980 80.0-100.0 578.6-723.3

27 41 1295 132.5 958.4 1150-1440 118.0-147.0 853.5-1063.3

30 46 1720 175.0 1265.8 1520-1910 155.0-195.0 1121.1-1410.4
33 50 2210 225.0 1627.4 1960-2450 200.0-250.0 1446.6-1808.3
36 55 2750 280.0 2025.2 2450-3040 250.0-310.0 1808.3-2242.2
39 60 3280 335.0 2423.1 2890-3630 295.0-370.0 2133.7-2676.2

Apply the following table for Hydraulic Hose.

Width Tightening torque

Hose
across
nominal Target valve Service limit
flat
number
a(mm) N·m kgf·m lbft N·m kgf·m lbft
02 19 44 4.5 32.5 35-63 3.5-6.5 25.3-47.0
22 74 7.5 54.2 54-93 5.5-9.5 39.8-68.7
03
24 78 8.0 57.9 59-98 6.0-10.0 43.4-72.3
04 27 103 10.5 75.9 84-132 8.5-13.5 61.5-97.6
05 32 157 16.0 115.7 128-186 13.0-19.0 94.0-137.4
06 36 216 22.0 159.1 177-245 18.0-25.0 130.2-180.8

4 - 12
.

MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

For using the machine safely for an extended period of time, you must periodically replace the safety critical and fire
prevention-related parts listed in the table of important parts.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is required
to replace them with new ones regardless of their condition after a certain period of usage. This is important to
ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the periodic
replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also carry out the following checks with hydraulic hoses which need not be replaced periodically. Tighten a loosened
clamp or replace a defective hose, as required.
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.

SAFETY CRITICAL PARTS

No. Safety critical parts for periodic replacement Q'ty Replacement interval
Fuel hose (fuel tank - water separator - fuel feed pump
1 4
- fuel filter - injection pump)
2 Spill hose (injection pump - fuel tank) 1
3 Hose (transmission cooler - transmission) 2
4 Hose (transmission valve - PPC valve) 2 Every 2 years or 4000 hours,
whichever comes sooner
5 Hose (transmission case - PPC valve) 1
6 Hose (PPC valve - steering cylinder) 2
7 Hose (PPC valve - brake cylinder) 2
8 Brake cylinder hose (between brake cylinder) 2
9 Seat belt (if equipped) 1 Every 3 years

4 - 13
.

MAINTENANCE SCHEDULE CHART MAINTENANCE

MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART

INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
Replace fuel filter cartridge 4- 46
Change oil in engine oil pan, replace engine oil filter cartridge 4- 48
Change oil in bevel gear case, transfer case 4- 51
Change oil in transmission case, clean strainer 4- 52
Change oil in final drive case 4- 53
Change oil in hydraulic tank, replace hydraulic oil filter cartridge 4- 54

WHEN REQUIRED
Check, clean and replace air cleaner element 4- 17
Clean inside of cooling system 4- 20
Clean water separator element 4- 22
Check and adjust steel shoe tension 4- 23
Check and tighten track steel shoe bolts 4- 25
Check and replace rubber shoes 4- 26
Check and adjust rubber shoe tension 4- 28
Replace rubber shoes 4- 30
Reverse and replace end bits and cutting edges 4- 33
Bleed air from head end of angle circuit 4- 34
Adjust brake pedal (test, adjust steering brake) 4- 35
Adjust idler clearance 4- 37

CHECK BEFORE STARTING

EVERY 50 HOURS SERVICE

Drain water, sediment from fuel tank 4- 39

EVERY 250 HOURS SERVICE

Lubricating 4- 40
Check oil level in final drive case, add oil 4- 42
Check oil level in hydraulic tank, add oil 4- 42
Check level of battery electrolyte 4- 43
Check fan belt tension, adjust 4- 45

EVERY 500 HOURS SERVICE

Replace fuel filter cartridge 4- 46
Change oil in engine oil pan, replace engine oil filter cartridge 4- 48
Clean, check radiator fins 4- 49
Clean breather 4- 49

4 - 14
.

MAINTENANCE MAINTENANCE SCHEDULE CHART

EVERY 1000 HOURS SERVICE

Check oil level in damper case, add oil 4- 50
Change oil in bevel gear case, transfer case 4- 51
Change oil in transmission case, clean strainer 4- 52
Change oil in final drive case 4- 53
Change oil in hydraulic tank, replace hydraulic oil filter cartridge 4- 54
Check oil in undercarriage components 4- 54
Check engine valve clearance, adjust 4- 54

EVERY 2000 HOURS SERVICE

Check alternator, starting motor 4- 55

EVERY 4000 HOURS SERVICE

Check water pump 4- 56

4 - 15
.

SERVICE PROCEDURE MAINTENANCE

SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)
Carry out the following maintenance only after the first 250 hours of operation on new machines.
Replace fuel filter cartridge
Change oil in engine oil pan, replace engine oil filter cartridge
Change oil in bevel gear case, transfer case
Change oil in transmission case, clean strainer
Change oil in final drive case
Change oil in hydraulic tank, replace hydraulic oil filter cartridge
For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS AND 2000 HOURS
SERVICE.

4 - 16
.

MAINTENANCE SERVICE PROCEDURE

WHEN REQUIRED

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

WARNING
Stop the engine before carrying out this operation. If inspection, cleaning, or maintenance is carried out with the engine
running, dirt will enter the engine and cause damage to the engine.
Immediately after the engine is stopped, the surface of the muffler is at high temperature. Be careful not to touch the muffler
when carrying out cleaning or replacement.
If compressed air is used when cleaning, dust will fly and may cause personal injury.
Always wear protective glasses, dust mask, and other protective clothing.

CHECKING
If air cleaner clogging caution lamp (1) lights up, clean the outer
element of the air cleaner.

NOTICE
Do not clean the element until the air cleaner clogging caution lamp on the
monitor panel lights up. If the element is cleaned frequently before the air
cleaner clogging caution lamp on the monitor lights up, the air cleaner will
not be able to display its proper performance and the cleaning efficiency
will go down.
In addition, the frequency of dust stuck to the element falling inside the
inner element will increase.

CLEANING OR REPLACING OUTER ELEMENT

1. Open the cover on top of the engine hood.

2. Remove three clips (2), then remove cover (3).

4 - 17
.

SERVICE PROCEDURE MAINTENANCE

NOTICE
Never remove inner element (5). If it is removed, dust will enter and cause
engine trouble.

3. Remove outer element (4).

4. Clean the interior of the air cleaner body, cover (3) and evacuator valve (6).

NOTICE
The inner element must not be used again even after its cleaning. When
replacing the outer element, replace the outer element at the same time.

5. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2, 99.4

PSI)) from the inside of the outer element along its folds. Then
direct the compressed air from the outside along the folds, and
again from the inside.
1) Replace any outer element, which has been cleaned 6
times or used for one year. Replace the inner element at
the same time.
2) Replace both inner and outer elements when the air cleaner clogging caution lamp lights up immediately
after installing the cleaned outer element even though it has not been cleaned 6 times.

6. If small holes or thinner parts are found on the element when

it is checked by shining a light through it after cleaning, replace
the element.

NOTICE
When cleaning the element, do not hit or beat it against anything.
Do not use an element whose folds, gasket or seal are damaged.

7. Before installing the outer element, check that the inner element is fitted securely. If the inner element is not
fitted securely, push it in properly.

8. Set the cleaned outer element (4) in position.

9. Set the arrow mark on cover (3) at the top, install to the air
cleaner body, then secure with clip (2).

4 - 18
.

MAINTENANCE SERVICE PROCEDURE

REPLACING ELEMENT
1. Open the cover on top of the engine hood.

2. Remove three clips (2), then remove cover (3).

3. Remove outer element (4).

Do not remove inner element (5) at this time, however.
4. Clean the interior of the air cleaner body, cover (3) and
evacuator valve (6).
5. Remove inner element (5), then quickly install the new inner
element.
Push the inner element in properly and check that it is fitted
securely.
6. Set the new outer element (4) in position.

7. Set the arrow mark on cover (3) at the top, install to the air
cleaner body, then secure with clip (2).

4 - 19
.

SERVICE PROCEDURE MAINTENANCE

CLEAN INSIDE OF COOLING SYSTEM

WARNING
Immediately after the engine is stopped, the cooling water is still hot and the internal pressure of the radiator is high. If the
radiator cap is removed and the coolant drained in this condition, it will cause burns. Wait for the temperature to go down, then
turn the cap slowly to release the internal pressure.
The engine is started when carrying out the washing operation. Before standing up from the operator's seat, always set the
safety lock lever to the LOCK position.
When starting the engine, see "CHECK BEFORE STARTING ENGINE, ADJUST (PAGE 3-19)" and "STARTING ENGINE (PAGE
3-32)" in the OPERATION section.
There is danger of touching the fan when the cover has been removed.
When the engine is running, never go in front of the machine.

Stop the machine on level ground when cleaning or changing the coolant.

When flushing the inside of the cooling system, do as follows.

Cleaning inside of
Adding corrosion
Kind of coolant cooling system and
resistor agent KI
changing coolant
Every year (autumn) or
Permanent type antifreeze
every 2000 hours
(All season type)
whichever comes first
Non-permanent type Every 6 months (spring Every 1000 hours and
antifreeze containing and 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

Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol.
In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corrosion
resistor agent contains 100g (0.22 lb). The standard density of the mixture should be 7g/liter (0.065 oz/US gal).
The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect,
a minimum ratio of 30% by volume is necessary.
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 (18°F) lower when deciding the mixing rate.

Mixing rate of water and antifreeze

Min. °C Avobe -10 -15 -20 -25 -30

atmospheric
temperature °F Avobe 14 5 -4 -13 -22

Amount of Liters 3.24 3.89 4.43 4.97 5.4

antifreeze US gal 0.86 1.03 1.17 1.31 1.43
Amount of Liters 7.56 6.91 6.37 5.83 5.4
water US gal 1.99 1.82 1.68 1.54 1.42

4 - 20
.

MAINTENANCE SERVICE PROCEDURE

WARNING
Antifreeze is flammable, so keep it away from flame.
Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on you. If it gets in your eyes,
flush your eyes with large amount of fresh water and see a doctor at once.

Use city water for the cooling water.

If river water, well water or other such water supply must be used, contact your Komatsu distributor.
We recommend use of an antifreeze density gauge to control the mixing proportions.

Prepare a container to catch drained coolant minimum 11 liters (2.91 US gal) capacity.

1. Stop the engine.

2. Turn radiator cap (1) slowly until it hits the stopper and by so
doing, relieving the internal pressure.
3. Turn radiator cap (1) until it hits the next stopper, while
depressing it. Keep turning the radiator cap (1) until it hits the
last stopper.
4. Put containers to catch the coolant under drain valve (2) at the
bottom of the radiator and under drain valve (3) at the side of
the cylinder block.
Open drain valve (2) and drain valve (3), and drain the water.
5. After draining the antifreeze solution, close drain valve (2), (3),
then fill with clean water. After the radiator is filled with water,
start and run the engine at low idling speed. After the water
temperature rises above 90°C (194°F), run the engine for
about 10 minutes.
6. Stop the engine and open drain valve (2), (3) to drain the water.
7. Add cooling water until it overflows from the water filler.
Decide the proportions of antifreeze and water according to the
table for the mixing rate of water and antifreeze.

8. After the engine warming up, check that each gauge and caution lamp are in normal condition. If any abnormality
is found, carry out adjustment or repairs.
Operate the machine under a light load until the engine water temperature gauge (2) points to the white range
(monitor panel spec.) or the green range(gauge panel spec.).
To remove the air in the cooling water, run the engine for 5 minutes at low idling, then for another 5 minutes at
high idling. (While doing this, leave the radiator cap removed)
9. Drain the cooling water inside sub-tank (4), clean the inside of
the sub-tank, then fill again with cooling water to a point
midway between the FULL and LOW marks.
10. Stop the engine. About 3 minutes later, supply city water up to
the water filler, then close radiator cap.

4 - 21
.

SERVICE PROCEDURE MAINTENANCE

CLEAN WATER SEPARATOR ELEMENT

WARNING
Do not bring any fire or flame close.

Prepare a filter wrench

Prepare a container to catch the fuel that is drained.

1. Open the inspection window in the right engine side cover.

2. Set handle (1) to OFF position (A).

3. Loosen drain plug (2), drain the fuel inside element cup (3),
then close drain plug (2).
4. Using a filter wrench, loosen the ring (4), take out element cup
(3), then remove element (5).
Be careful not to lose red ring (6) inside the cup.
5. Wash element (5) and the inside of element cup (3) with diesel
fuel or flushing oil.

6. After washing, install element (5).

7. Insert red ring (6) inside element cup (3), fill with fuel, install to the filter holder, then tighten ring (4).
Tightening torque: 14.7 to 19.6 N·m (1.5 to 2.0 kgf·m, 10.8 to 14.5 lbft)
8. Set handle (1) to ON position (B).
9. After completing the washing of the water separator, bleed the air.
For details of the method of bleeding the air, see "METHOD OF USING AUTOMATIC AIR BLEED
MECHANISM (PAGE 4-46)".

4 - 22
.

MAINTENANCE SERVICE PROCEDURE

CHECK AND ADJUST STEEL SHOE TENSION

The wear of pins and bushings on the undercarriage will vary with the working conditions and types of soil. It is thus
necessary to continually inspect the track tension so as to maintain the standard tension.
Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track
becomes clogged with mud, measure with the track clogged with mud).

CHECKING
Stop the machine on level ground (travel forward and stop the
machine without applying the brake).
Put a straight bar between the carrier roller and idler as shown in
the diagram on the right and measure clearance A between the bar
and the grouser at the center. The tension (clearance A) should be
20 to 30 mm (0.8 to 1.2 in).
If the tension is not the standard value, adjust as follows.

ADJUSTMENT

WARNING
There is danger of plug (1) flying out under the high internal pressure of the
grease. Never loosen plug (1) more than 1 turn.
Never loosen any part other than plug (1). Never put your face in the
mounting direction of plug (1).
If the track tension cannot be loosened with the procedure given here,
please contact your Komatsu distributor.

INCREASING TRACK TENSION

Prepare a grease gun.
1. Pump in grease through grease fitting (2) with a grease pump.
2. To check that the correct tension has been achieved, move the
machine backwards and forwards.
3. Check the track tension again, and if the tension is not correct,
adjust it again.

4 - 23
.

SERVICE PROCEDURE MAINTENANCE

4. Continue to pump in grease until dimension S becomes zero

(0). 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 for repairs.

LOOSENING TRACK TENSION

WARNING
It is extremely dangerous to release the grease by any method except the procedure given below.
If the track tension is not relieved by this procedure, please contact your Komatsu distributor for repairs.

1. Loosen plug (1) gradually to release the grease.

2. When loosening plug (1), turn it a maximum of one turn.
3. If the grease does not come out smoothly, move the machine
forwards and backwards a short distance.
4. Tighten plug (1).
5. To check that the correct tension has been achieved, move the
machine backwards and forwards.
6. Check the track tension again, and if the tension is not correct,
adjust it again.

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MAINTENANCE SERVICE PROCEDURE

CHECK AND TIGHTEN TRACK STEEL SHOE BOLTS

If the machine is operated with loose steel shoe bolts (1), the bolts
will break, so tighten any loose bolts immediately.

METHOD FOR TIGHTENING (SHOE BOLT)

1. First, tighten to a tightening torque of 68.6 ± 9.81 N·m (7 ± 1 kgf·m), then check that the nut and shoe are in tight
contact with the mating surface of the link.
2. After checking, tighten a further. 90° ± 10°.

METHOD FOR TIGHTENING (MASTER LINK CONNECTING BOLT)

1. First, tighten to a tightening torque of 68.6 ± 9.81 N·m (7 ± 1 kgf·m), then check that the mating surfaces of the
link are in tight contact.
2. After checking, tighten a further 180° ± 10°.

ORDER FOR TIGHTENING

Tighten the bolts in the order shown in the diagram on the right.

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SERVICE PROCEDURE MAINTENANCE

CHECK AND REPLACE RUBBER SHOES

If the rubber shoes are in the following condition, they must be repaired or replaced, so please contact your Komatsu
distributor for repair or replacement.

LUG HEIGHT
(A): Track roller (B): Rubber shoe

If lug height "a" is reduced by wear, the drawbar pull will drop.
If "a" has reached the following value, replace with a new part.
D21A: 20 mm (0.8 in) or less
D21P: 25 mm (1.0 in) or less
When working in conditions where there is no drop in the
drawbar pull caused by shoe slippage, it is possible to use the
rubber shoes until lug height "a" goes down to 5 mm (0.197 in).
If the lug height becomes less than 5 mm (0.197 in), replace with
a new part.
If the lug is worn and the steel cord inside the shoe is exposed
(C) for two or more links, replace with a new part.

RUBBER SHOE STEEL CODE CUTS

If more than half of the steel cord layer is cut, replace with a new
part.

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.

MAINTENANCE SERVICE PROCEDURE

RUBBER SHOE CORE SEPARATIONS

If the core of the rubber shoe has separated (A) at one place or
more, replace with a new part.

RUBBER SHOE TENSION

If the rubber shoe is still slack even when grease is pumped in, replace with a new part or replace the seal inside
the cylinder.
If the track tension can only be increased to a level where the rubber shoe may come off, there may be not only
elongation of the rubber shoe but also damage to the grease cylinder.

RUBBER SHOE CRACKS

If cracks (A) have appeared between the rubber shoe lugs, carry
out repairs when the length becomes more than approx. 60 mm
(2.4 in). However, even if the damage is small or short, carry out
repairs immediately if the internal steel cord can be seen.

REMARK
If the length of the crack is less than 30 mm (1.2 in) or the depth is
less than 10 mm (0.4 in), there is no particular need to carry out
repairs.
When deciding whether to continue to use, repair, or replace the
rubber shoe, please consult your Komatsu distributor.

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SERVICE PROCEDURE MAINTENANCE

CHECK AND ADJUST RUBBER SHOE TENSION

The wear of the rubber shoe will vary with the work conditions and type of soil, so inspect the wear and track tension
whenever necessary. Stop the machine on firm, horizontal ground when carrying out the inspection and
maintenance.
In particular, on new machines or after new tracks have been installed and the tension has been set to the specified
value, the track tension will become loose in the first 5 to 30 hours when the machine has been used for a certain
amount of repeated
travel. If the track tension is adjusted frequently until the initial loosening no longer occurs, this will prevent the shoes
from coming off due to insufficient track tension.
If operations are carried out when the rubber shoe is loose, the track will come off and it will cause premature wear
of the core.

CHECKING
1. Run the engine at low idling, move the machine forward a
distance equal to the length of track on ground, then stop the
machine.
2. Choose wooden block (3) that will reach from idler (1) to carrier
roller (2), then place it on top of the track.
3. Measure the maximum deflection between the top surface of
the rubber shoe and the bottom surface of the wooden block.
Standard deflection
Deflection "a" should be 1 to 3 mm (0.039 to 0.118 in).

If the track tension is not at the standard value, adjust it in the following manner.

ADJUSTMENT

WARNING
There is danger of the plug flying out under the high internal pressure of
the grease. When loosening plug (1), never loosen it more than one turn.
Never loosen any part other than plug (1). Never put your face in line with
the mount of plug (1).
If the Rubber shoe tension is not relieved by this procedure, please contact
your Komatsu distributor.

INCREASING TRACK TENSION

Prepare a grease gun.
1. Pump in grease through grease fitting (2) with a grease pump.
2. To check that the correct tension has been achieved, move the
machine backwards and forwards.
3. Check the rubber shoe tension again, and if the tension is not
correct, adjust it again.
4. If the track tension is still loose after grease is pumped in, it is
necessary to replace the rubber shoe or replace the seal inside
the cylinder. Please contact your Komatsu distributor for
replacement.

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MAINTENANCE SERVICE PROCEDURE

LOOSENING TRACK TENSION

WARNING
It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not
relieved by this procedure, please contact your Komatsu distributor.

1. Loosen plug (1) gradually to release the grease.

2. When loosening plug (1), turn it a maximum of one turn.
3. If the grease does not come out smoothly, move the machine
forwards and backwards a short distance.
4. Tighten plug (1).
5. To check that the correct tension has been achieved, move the
machine backwards and forwards.
6. Check the rubber shoe tension again, and if the tension is not
correct, adjust it again.

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.

SERVICE PROCEDURE MAINTENANCE

REPLACE RUBBER SHOES

WARNING
Carry out this operation with two workers. The operator must move the
machine in accordance with the signals from the other worker.
The rubber shoes are replaced with the machine raised, so it is
extremely dangerous if the machine is lowered by mistake during the
replacement operation. During the replacement operation, never move
the rubber shoe track except the rubber shoe track to be replaced.
In addition, never go under or put any part of your body under the rubber
shoe or track frame during the replacement operation.
To check that the track tension is correct, run the engine at low idling,
move the machine forward a distance equal to the length of track on
ground, then stop the machine.

Prepare a grease gun

Prepare a steel pipe
1. Jack up the undercarriage. For details, see "METHOD OF RAISING UNDERCARRIAGE (PAGE 4-32)".

RUBBER SHOES REMOVAL

WARNING
It is extremely dangerous to release the grease by any method except the procedure given below.
If the rubber shoe tension is not relieved by this procedure, please contact your Komatsu distributor for repairs.
Check that all the grease has been released before rotating the sprocket to remove the rubber shoe.

1. Loosen plug (1) gradually to release the grease.

2. When loosening plug (1), turn it a maximum of one turn.

3. Fit steel pipes (2) inside the rubber shoe, rotate the sprocket in
reverse direction (A), and when steel pipes (2) make the rubber
shoes come up from the idler, slide the rubber shoes to the side
in direction (B) and remove them.

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MAINTENANCE SERVICE PROCEDURE

RUBBER SHOES INSTALLATION

1. Mesh the rubber shoe with the sprocket and fit it over the idler.
2. Rotate the sprocket in reverse direction (A) and push the
rubber shoe in to stop the rotation.

3. Fit steel pipes (2) inside the rubber shoe, rotate the sprocket
again in reverse direction (A), and fit the rubber shoes securely
on the idler.
4. Stop the rotation, and check that the rubber shoe is securely
fitted to the sprocket and idler.

5. Adjust the tension of the rubber shoe. For details, see "CHECK AND ADJUST RUBBER SHOE TENSION
(PAGE 4-28)".
6. Check again that the rubber shoe is securely fitted to the sprocket and idler and that the track tension is correct,
then lower the machine to the ground.

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.

SERVICE PROCEDURE MAINTENANCE

METHOD OF RAISING UNDERCARRIAGE

WARNING
Always carry out the operation on a firm, horizontal ground surface.

METHOD OF LIFTING WITH WIRE CABLE

1. Pass a wire cable through the drawbar, fit a wooden block
between the cable and chassis to prevent the cable from
rubbing against the chassis, then raise the machine.
2. Insert a wooden block under the steering case to keep the
machine stable.
Height (H) of wooden block: Approx. 450 mm (17.7 in).

3. Lower the blade and jack up the machine so that the track is
horizontal.

METHOD OF JACKING UP
1. Fit 2 jacks with a capacity of at least 10 tons under the bottom
surface of the steering case and jack up the machine so that
the track comes off the ground.

2. Lower the blade and jack up the machine so that the rubber
shoe assembly is horizontal.

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.

MAINTENANCE SERVICE PROCEDURE

REVERSE AND REPLACE END BITS AND CUTTING EDGES

WARNING
It is dangerous if the work equipment moves by mistake when the cutting edges and end bits are being reversed or replaced.
Set the work equipment in a stable condition, then stop the engine and lock the blade control lever securely with the safety lock
lever.

Reverse or replace the cutting edge and end bit before the end face of the blade starts to wear.
1. Raise the blade to a proper height and apply a block to the
frame so as to prevent fall of the blade.
2. Remove the cutting edge and the end bit and clean the
mounting surface.

REMARK
If the cutting edge and the end bit on both sides are worn out,
replace with new one.
If it has been worn out up to the fitting surface, repair the fitting
surface and then reverse or replace.
3. Reverse or replace the cutting edge and end bit, and install.
Tightening torque of mounting nut: 127 ± 19.6 N·m (13 ± 2 kgf·m)
If bolt (1) or nut (2) are damaged, replace them at the same time.
4. After operating the machine for a few hours, tighten the mounting nuts again.

4 - 33
.

SERVICE PROCEDURE MAINTENANCE

BLEED AIR FROM HEAD END OF ANGLE CIRCUIT

HYDRAULIC ANGLE-TILT DOZER

WARNING
When loosening the oil filler cap, oil may spurt out, so turn it slowly to release the internal pressure, then loosen it carefully.

After removing, repairing, or installing the work equipment, do as follows.

1. Loosen the cap of the hydraulic tank.
2. Start the engine, raise the blade approx. 300 mm (11.8 in) from the ground (level with or higher than the frame),
then run the engine at low idling.
3. With the engine at low idling, operate the left and right tilt cylinders fully to the end of the stroke in turn approx.
10 times repeatedly to fill the tilt circuit with oil.
4. Angle the blade fully to the left, loosen plug (1) 3 turns, then
loosen valve (3) 2 turns.
5. With the engine at low idling, operate the right tilt continuously
until no more bubbles come out with the oil from plug (1).
Check that there are no more bubbles in the oil, then tighten
plug (1).
Operate the tilt slowly with the engine running at low idling.
6. Angle the blade fully to the right, then loosen plug (2) 3 turns.
7. With the engine at low idling, operate the right tilt continuously
until no more bubbles come out with the oil from plug (2).
Check that there are no more bubbles in the oil, then tighten
plug (2).
Operate the tilt slowly with the engine running at low idling.
8. Tighten valve (3).
Tightening torque: 24.5 ± 4.9 N·m (2.5 ± 0.5 kgf·m)
9. After completely bleeding the air, check the oil level in the hydraulic tank and add oil if necessary. Then tighten
the hydraulic tank cap and wipe off all the oil from around the cylinder.

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.

MAINTENANCE SERVICE PROCEDURE

ADJUST BRAKE PEDAL (TEST, ADJUST STEERING BRAKE)

If the brake pedal travel is excessive, the brake lining is probably worn, so adjust as follows.

ADJUSTMENT
Adjust both the left and right brakes.
1. Remove the rear cover, then remove inspection cover (1).

2. Tighten adjustment nuts (2) and (3) (tightening torque: 39 N·

m (4 kgf·m)) to bring the lining into close contact with the drum,
then turn nuts (2) and (3) back 4 turns.
3. Check the travel of the brake pedal. For details, see "CHECK
BRAKE PEDAL TRAVEL (PAGE 3-25)".
When doing this, the standard clearance between the lining
and the drum is 1 mm (0.04 in).
Basically, this completes the adjustment of the brake band
clearance, but to check that the clearance between the lining
and drum is the same on both the left and right sides, do as
follows.
If there is any difference between the clearance of the left and
right brakes, the brakes will pull to one side.

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SERVICE PROCEDURE MAINTENANCE

TEST, ADJUST RIGHT STEERING BRAKE

1. Look through inspection window (4) under the operator's seat.
Pin (5) is installed to an oblong yoke beyond the oil level gauge
tube. Hook the end of a steel tape measure to the projecting
part at the tip of pin (5).
2. Depress the brake pedal fully and measure the amount of
movement of the tape measure (pin (5)).
3. When reading the movement of the tape measure, use edge
(6) of the inspection window as a benchmark.
If movement (A) is 14.5 mm (0.6 in), the brake is correctly
adjusted.
If it is not 14.5 mm (0.6 in), carry out fine adjustment of
movement (A) with right adjustment nut (3) as follows.
If it is LESS than 14.5 mm (0.6 in), LOOSEN nut (3).
If it is MORE than 14.5 mm (0.6 in), TIGHTEN nut (3).

TEST, ADJUST LEFT STEERING BRAKE

1. Travel (A) at the tip of the pedal should be 98 mm (3.9 in) when
the brake pedal is fully depressed.
If it is not 98 mm (3.9 in), adjust again with left adjustment nut
(2).

The movement of pin (5) and the travel of the brake pedal change
as follows when left and right adjustment nuts (2) and (3) are turned
1/2 turn.
Change in movement of pin (5): 1.6 mm (0.063 in)
Change in travel of brake pedal: 11 mm (0.4 in)
If the braking effect is still poor even after adjustment, please ask
your Komatsu distributor to carry out repairs.

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.

MAINTENANCE SERVICE PROCEDURE

ADJUST IDLER CLEARANCE

Since the idlers are forced to move forward and backward by an external force guide plates will be worn out.
Wear of these plates will cause the vibration of idlers from side to side or inclination of the idlers, and running off of
track links from the idlers or unevenly worn idler and links may result.
Therefore, adjust the idlers according to the following procedure.

ADJUSTMENT
1. Travel for 1 or 2 meters on flat ground, then measure clearance
(A) between track frame (1) and guide plate (2) (4 places: left,
right, inside, outside).
2. If clearance (A) is more than 1.5 mm (0.06 in), loosen bolt (3),
remove the shim, and adjust the shim thickness on one side to
0.5 mm (0.02 in).
Thickness of one shim is 1.0mm (0.04 in).

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SERVICE PROCEDURE MAINTENANCE

CHECK BEFORE STARTING

For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-21)" in the OPERATION section.
Check coolant level, add water
Check fuel level, add fuel
Check oil level in engine oil pan, add oil
Check oil level in bevel gear case,transter case,add oil
Check oil level in transmission case, add oil
Check brake pedal travel
Check, drain water separator
Check horn sound
Check electric wirings
Check that lamps light up
Check of operation of instruments

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.

MAINTENANCE SERVICE PROCEDURE

EVERY 50 HOURS SERVICE

DRAIN WATER, SEDIMENT FROM FUEL TANK

Carry out this check before operating the machine.
Prepare a container to catch the fuel that is drained.

1. Open drain valve(1) at the bottom of the tank to drain sediment

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

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.

SERVICE PROCEDURE MAINTENANCE

EVERY 250 HOURS SERVICE

Maintenance for every 50 hours service should be carried out at the same time.

LUBRICATING
1. Lower the blde 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.

POWER ANGLE, POWER TILTDOZER

1. Angle, tilt frame center pin (1 place)

2. Brace pin (2 places)
3. Lift cylinder bottom pin (2 places)
4. Lift cylinder head end (2 places)
5. Angle, tilt frame support pin (2 places)
6. Angle cylinder head pin (2 places)
7. Tilt cylinder head pin (1 place)
8. Tilt cylinder bottom pin (1 place)
9. Angle cylinder bottom pin (2 places)

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.

MAINTENANCE SERVICE PROCEDURE

POWER TILTDOZER

1. Lift cylinder yoke (8 places)

2. Lift cylinder head pin (2 places)
3. Tilt cylinder head pin (1 place)
4. Tilt brace pin (2 places)
5. Center brace pin (4 places)

4 - 41
.

SERVICE PROCEDURE MAINTENANCE

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

WARNING
The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting
the operation.
If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.

Prepare a handle.
1. Remove plug (F) on the left and right, and check that the oil
level is near the bottom of the plug hole.
2. If the oil level is low, add oil through the hole of plug (F). Add
oil until oil overflows from the hole of plug (F).

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down
before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

NOTICE
Do not add oil above the H line. This will damage the hydraulic circuit or
cause the oil to spurt out. If oil has been added to above the H level, stop
the engine and wait for the hydraulic oil to cool down, then drain the excess
oil from drain plug (P).

1. Lower the blade to the ground and stop the engine. Wait for
about 5 minutes before checking oil level. If the oil level should
be between H and L in sight gauge (G).
2. If the level is below the L mark, add oil through oil filler (F).

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.

MAINTENANCE SERVICE PROCEDURE

CHECK LEVEL OF BATTERY ELECTROLYTE

Carry out this check before operating the machine.

WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the
inside of the battery and reduce the service life of the battery. In addition, it may also cause an explosion.
The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the
electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.

NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from
freezing.

Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.

WHEN CHECKING ELECTOLYTE LEVEL FROM SIDE OF BATTERY

If it is possible to check the electrolyte level from the side of the battery, check as follows.
1. Open cover (1) at the rear of the operator's seat.
2. Use a wet cloth to clean the area around the electrolyte level
lines and check that the electrolyte level is between the
UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.

3. If the electrolyte level is below the midway point between the

U.L and L.L lines, remove cap (2) and add distilled water to the
U.L line.
4. After adding distilled water, tighten cap (2) securely.

REMARK
If distilled water is added to above the U.L. line, use a syringe to
lower the level to the U.L. line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it away with a large
amount of water or consult your Komatsu distributor or battery
maker.

4 - 43
.

SERVICE PROCEDURE MAINTENANCE

WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SYDE OF BATTERY

If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Open the battery room door and remove sheet (1) installed
above the battery.
2. Remove cap (2) at the top of the battery, look though the water
filler port, and check the electrolyte surface. If the electrolyte
does not reach the sleeve, add distilled water so that the level
reaches the bottom of the sleeve (UPPER LEVEL line) without
fail.

Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.

3. After adding distilled water, tighten cap (2) securely.

REMARK
If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the
sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount
of water or consult your Komatsu distributor or battery maker.

WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL

If it is possible to use and indicator to check the electrolyte level, follow the instructions given.

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.

MAINTENANCE SERVICE PROCEDURE

CHECK FAN BELT TENSION, ADJUST

INSPECTION
Push a point midway between alternator pulley (1) and fan pulley
(2) with a finger force of approx. 98.1 N·m (10 kgf·m).
Standard deflection (A): Approx. 10 to 15 mm (0.4 to 0.6 in)
Standard deflection when the belt is new: Approx. 7 to 9 mm (0.28
to 0.36 in)

ADJUSTMENT
Prepare a pinch bar.
Prepare a wooden block.

1. Insert a bar between alternator (1) and the cylinder block to fix
alternator (1) in position.
When fixing the alternator in position, put a piece of wood
between the bar and alternator (1) to prevent damage to
alternator (1).
2. Loosen bolt (2) and nut (3).
3. Move alternator (1) with the bar so that the deflection of the belt
is approx. 10 to 15 mm (0.4 to 0.6 in) (new belt: approx. 7 to 9
mm (0.28 to 0.36 in)) when pressed with a finger force of
approx. 98.1 N·m (10 kgf·m).
4. Tighten bolt (2) and nut (3) to secure alternator (1) in position.

NOTICE
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.
In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts with new ones.
• The fan belt has elongated, leaving little allowance for adjustment.
• A cut or crack is found on the belt.
• Slipping or creaking sound is heard coming from the belt.
When the new V-belt is set, readjust it after one hour of operation.

4 - 45
.

SERVICE PROCEDURE MAINTENANCE

EVERY 500 HOURS SERVICE

Maintenance for every 50 and 250 hours service should be carried out at the same time.

REPLACE FUEL FILTER CARTRIDGE

WARNING
Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing
the filter.
Do not bring fire or sparks near the fuel.

Prepare a filter wrench and a container to catch the fuel.

1. Set the container to catch the fuel under the filter cartridge.
2. Using a filter wrench, turn filter cartridge (1) 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. Bring the packing surface into contact with the seal surface of
the filter holder, then tighten a further approx. 2/3 turns.
If the filter cartridge is tightened too much, the packing will be
damaged and this will cause leakage of fuel. If it is not
tightened enough, there will be a gap at the packing and this
will also cause leakage of fuel. To avoid this problem, always
tighten to the proper tightening angle.
5. After replacing the filter cartridge, bleed the air as follows, then start the engine and check for leakage of fuel
from the filter seal. If there is any leakage, check the tightening of the filter cartridge. If there is still leakage,
repeat Steps 1 and 2 to remove the filter cartridge and check for damage or dirt caught in the packing surface.
If there is any damage or dirt caught in the packing surface, replace the packing with a new part and repeat Steps
3 to 5 to install the new cartridge.

METHOD OF USING AUTOMATIC AIR BLEED MECHANISM

WARNING
The engine will start, so check carefully that the area around the engine is safe before cranking it.

It is possible to bleed the air from the fuel circuit simply by turning the starting switch to the ON position.
After replacing the filter cartridge or draining the water from the water separator, bleed the air as follows.

REMARK
After filling the fuel tank when the machine has run out of fuel, use the same procedure to bleed the air.
If the fuel tank is full, it takes less time to bleed the air.

4 - 46
.

MAINTENANCE SERVICE PROCEDURE

1. Pull the fuel control lever to the mid-range speed position.

2. Set the safety lock lever (for the steering, direction, and speed
lever) to LOCK position (L).

3. Turn the key in the starting switch to the ON position (B) and
hold it there for 30 to 60 seconds.
When the key is turned to the ON position (B), the fuel feed
pump is actuated and the air is automatically bled.

4. Turn the key in the starting switch to the START position (C) to
start the engine.

If the air is not completely bled with the operation in Step 3, the
engine may stop, but simply start the engine again.

NOTICE
Do not continue to crank the starting motor for more than 20 seconds. Wait
for 1 or 2 minutes, then try again.

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.

SERVICE PROCEDURE MAINTENANCE

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns. Wait for the
temperature to go down before starting the operation.

Refill capacity: 6.6 liters (1.74 US gal)

Prepare a socket wrench and filter wrench.

1. Remove the cover on the bottom of the machine and set a container to catch the drained oil directly under the
drain plug.
2. Taking care not to get oil over yourself, remove drain plug (P)
slowly 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 (P).

5. Using a filter wrench, turn the filter cartridge (1) to the left and
remove it.
When doing this, to avoid getting oil over yourself, do not carry
out the operation from directly under the cartridge.
In particular, if the operation is carried out immediately after the
engine has been stopped, a large amount of oil will come out,
so wait for 10 minutes before draining the oil.
6. Clean the filter holder, coat the packing surface of the new filter
cartridge with engine oil, or coat thinly with grease), then install
it to the filter holder.
7. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten a
further 1/2 turn.
8. After replacing the filter cartridge, add engine oil through oil filler port (F) to between the H and L lines on the level
gauge.
When adding oil, be careful not to get oil on the alternator.
9. Run the engine at idling for a short time, then stop the engine, and check that the oil level is between the H and
L marks on the dipstick. For details, see "CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL (PAGE 3-23)".

4 - 48
.

MAINTENANCE SERVICE PROCEDURE

CLEAN, CHECK RADIATOR FINS

WARNING
If compressed air, high-pressure water, or steam hit your body directly, or they cause dirt or dust to be blown up, there is a hazard
of serious injury. Always use safety glasses, dust mask, or other protective equipment.

1. Remove bolts (1), then remove radiator grille (2).

2. Clean the radiator fins clogged with mud, dust and leaves with
compressed air. Steam or water may be used instead of
compressed air.
3. Check the rubber hose. Replace with a new one if the hose is
found to have cracks or to be hardened by ageing.
Also, check hose clamps for looseness.

CLEAN BREATHER
Remove the breather, then rinse the dirt out from the inside with diesel oil or flushing oil.
1. Transmission case breather (1 place)

2. Bevel gear case, transfer case breather (1 place)

3. Damper case breather (1 place)

4 - 49
.

SERVICE PROCEDURE MAINTENANCE

EVERY 1000 HOURS SERVICE

Maintenance for every 50, 250 and 500 hours should be carried out at the same time.

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to
go down before starting the operation.

If the quantity of the oil in the damper is insufficient, the damper may be seized. Accordingly, check, and add or
replace the oil according to the following procedure.
1. Remove plug (G) and check that the oil level is near the bottom
of the plug hole.
2. If the oil level is correct, install plug (G).

REMARK
Check the oil level while the engine is stopped.
If the machine is inclined, set it in a level position before
checking the oil level.

3. If the oil it is not up to near the bottom of the plug hole, remove
oil filler plug (F) and add oil to the near the bottom of the hole
of plug (G).
4. After adding oil, install plugs (F) and (G).

REMARK
If too much oil is added, the excess oil will flow out from the hole of
plug (G). Wait for the oil to stop flowing out, then install plug (G).

4 - 50
.

MAINTENANCE SERVICE PROCEDURE

CHANGE OIL IN BEVEL GEAR CASE, TRANSFER CASE

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to
go down before starting the operation.

Refill capacity: 13 liters (3.43 US gal)

Prepare a socket wrench.

1. Set a container to catch the oil under drain plug (P) at the
bottom of the machine.
2. Remove drain plug (P) slowly to avoid getting oil on yourself,
and drain the oil.
After draining the oil, tighten drain plug (P).

3. Refill the specified quantity of oil through oil filler (F).

4. After adding oil, check that the oil level is at the specified level.
For details, see "CHECK OIL LEVEL IN BEVEL GEAR CASE,
TRANSFER CASE, ADD OIL (PAGE 3-24)".

4 - 51
.

SERVICE PROCEDURE MAINTENANCE

CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to
go down before starting the operation.

Refill capacity: 11 liters (2.91 US gal)

Prepare a socket wrench.

1. Remove the cover under the machine, then set a container

under drain plug (P) to catch the oil.
2. Taking care not to get oil over yourself, remove drain plug (P)
slowly, drain the oil, then tighten drain plug (P) again.
3. Remove mounting bolt (1) of tube (4), remove mounting bolt (3)
at the bottom of strainer case (2), then remove tube (4).
4. Remove strainer (5).
If strainer (5) is damaged, replace it with a new part.
5. Remove all dirt stuck to the strainer, then wash the strainer in
clean diesel fuel or flushing oil. Wash the inside of the case
and the plug also.
6. After installing the strainer, refill with the specified amount of oil
through oil filler port (F).
7. After adding oil, check that the oil level is at the specified level.
For details, see "CHECK OIL LEVEL IN TRANSMISSION
CASE, ADD OIL (PAGE 3-24)".

8. Start the engine.

9. Set the steering, direction, and speed lever at the N position,
then operate it fully to the L position (steering to left). Next,
operate it to the R position (steering to right). Repeat this
operation approx. 10 times to fill the steering and brake circuits
with oil.
10. Travel in 1st and check that the machine turns properly to the
left and right.

4 - 52
.

MAINTENANCE SERVICE PROCEDURE

CHANGE OIL IN FINAL DRIVE CASE

WARNING
The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting
the operation.
If there is still pressure remaining inside the case, the oil or plug may fly out.
Loosen the plug slowly to release the pressure.

Refill capacity
D21A: each 6 liters (1.59 US gal)
D21P: each 8 liters (2.11 US gal)
Prepare a socket wrench.
Change the oil in the left and right final drive cases.

1. Set the container to catch the oil immediately under drain plug
(P).
2. Remove drain plug (P) and oil filler plug (F), drain the oil, then
tighten drain plug (P).
3. Refill the specified quantity of oil through oil filler (F).
4. Check that the oil is at the specified level. For details, see
"CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
(PAGE 4-42)".

4 - 53
.

SERVICE PROCEDURE MAINTENANCE

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER CARTRIDGE

WARNING
The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down
before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

Refill capacity: 21 liters (5.55 US gal)

Prepare the following.
Socket wrench, filter wrench

1. Lower the blade to the ground, stop the engine, then operate
the blade control lever to the front and rear (left and right).
Loosen the cap of oil filler port (F) slowly until it contacts the
stopper to release the internal pressure.
2. Push down the cap and turn it until it contacts the next stopper.
3. Place a container to catch the oil under drain plug (P).
4. Remove drain plug (P), drain the oil, then tighten drain plug (P).
When removing drain plug (P), be careful not to get oil over
yourself.

5. Using a filter wrench, turn filter cartridge (1) counterclockwise to remove it.
6. Clean the filter holder, fill the new filter cartridge with oil, then coat the seal and thread of the filter cartridge with
oil (or coat thinly with grease) and install.
7. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten
approx. 1/2 to 3/4 turns.
8. Refill the specified quantity of oil through oil filler (F).
9. After adding oil, check that the oil is up to the specified level. For details, see "CHECK OIL LEVEL IN
HYDRAULIC TANK, ADD OIL (PAGE 4-42)".

CHECK OIL IN UNDERCARRIAGE COMPONENTS

Check the amount of oil in the track roller, carrier roller, and idler as follows.
1. Stop the machine on level ground.
2. Loosen the seal bolt slowly. If oil oozes out, there is still
enough oil, so tighten the bolt again immediately.
3. If no oil comes out even when the seal bolt is removed, the oil
level is low, so please contact your Komatsu distributor for
repairs.

CHECK ENGINE VALVE CLEARANCE, ADJUST

Special tools are needed for inspection and maintenance, please contact your Komatsu distributor.

4 - 54
.

MAINTENANCE SERVICE PROCEDURE

EVERY 2000 HOURS SERVICE

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

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, have this inspection carried out every 1000 hours.

4 - 55
.

SERVICE PROCEDURE MAINTENANCE

EVERY 4000 HOURS SERVICE

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

CHECK WATER PUMP

Check that there is no play in the pulley, leakage of oil or water, or clogging of the drain hole. If any abnormality is
found, please contact your Komatsu distributor for repairs or replacement.

4 - 56
.

5-1
.

SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS
D21A-8 D21P-8
Item Unit
Steel shoes Rubber shoes Steel shoes Rubber shoes
kg 3,940 3,980 4,320 4,360
Machine weight
(lb) (8.688) (8,776) (9,526) (9,614)
Name of engine - Komatsu 4D94LE-2 diesel engine
Engine horsepower kW(HP)/rpm 29.4 (39) / 2450
mm 3,365 3,365 3,350 3,350
A Overall length
(ft in) (11'0") (11'0") (10'12") (10'12")
mm 2,450 2,440 2,475 2,450
B Overall height
(ft in) (8'0") (8'0") (8'1") (8'0")
mm 2,170 2,170 2,560 2,560
C Overall width
(ft in) (7'1") (7'1") (8'5") (8'5")
km/h 2.6/4.4 2.8/4.8 2.6/4.4 2.8/4.8
Forward
Travel speed (MPH) (1.6/2.7) (1.7/3.0) (1.6/2.7) (1.7/3.0)
(1st/2nd) km/h 3.3/5.6 3.6/6.1 3.3/5.6 3.6/6.1
Backward
(MPH) (2.1/3.5) (2.2/3.8) (2.1/3.5) (2.2/3.8)

5-2
.

6-1
.

GENERAL PRECAUTIONS ATTACHMENTS, OPTIONS

GENERAL PRECAUTIONS
PRECAUTIONS RELATED TO SAFETY
If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the
machine, but will also cause problems with safety.
When installing attachments not listed in this Operation and Maintenance Manual, contact your Komatsu distributor
first.
If you do not contact Komatsu, we cannot accept any responsibility for any accidents or failures.

WARNING
General precautions
Read the instruction manual for the attachment thoroughly, and do not use this attachment unless you are sure that you have
understood the guides completely.
If you lose the instruction manual, always ask the manufacturer or your Komatsu distributors for a new copy.
Depending on the attachment, install the necessary front guard to the machine.
Depending on the attachment, the impact noise may make it difficult for fellow workers to transmit instructions for the
operation. Before starting operation, decide a leader and determine the signals to be used.
Do not carry out swinging operations to the side with a heavy load on the attachment. This is particularly dangerous on slopes.
Comparing with a machine equipped with a bucket, a machine equipped with a breaker has a heavy load at the front of the work
equipment and is unstable. To avoid a hazard of tipping over, do not carry out operations with the attachment swung to the
side.
When an attachment is installed, the swing range and center of gravity of the machine are different, and the machine may move
in an unexpected way. Be sure that you understand the condition of the machine properly.
Before starting operations, set up a fence around the machine to prevent people from entering.
Never operate the machine when there are people near the machine.
To prevent serious accidents caused by misoperation, do not put your foot on the pedal except when operating the pedal.

Precautions for removal and installation operations

When removing or installing the attachments, obey the following precautions and take care to ensure safety during the operation.
Carry out the removal and installation operation on a flat, firm ground surface.
When the operation is carried out by two or more workers, determine the signals and follow these during the operation.
When carrying heavy objects (more than 25kg or 55 lb), use a crane.
When removing heavy parts, always support the part before removing it.
When lifting such as 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 it is 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 removal and installation operations, contact your Komatsu distributor.

6-2
.

ATTACHMENTS, OPTIONS DECELERATOR PEDAL

DECELERATOR PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.
When passing over the top of a hill or when a load is dumped over a cliff,
the load is suddenly reduced, so there is danger that the travel speed
will also increase suddenly. To prevent this, depress the decelerator
pedal to reduce the travel speed.

This pedal is used to reduce the engine speed or to stop the

machine.
When the pedal is depressed, the engine speed goes down.
Use this pedal to reduce speed when shifting between forward and
reverse or when stopping the machine.

6-3
.

SUSPENSION SEAT ATTACHMENTS, OPTIONS

SUSPENSION SEAT
ADJUSTMENT
WARNING
When adjusting the position of the operator's seat, always set the safety lock lever to the LOCK position to prevent any accidental
contact to the control levers.

Always adjust the operator's seat before starting each operation or when the operators change shift.
When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can
be fully depressed.

Fore-aft adjustment of seat

Move lever (1) to the left, set the seat to the desired position, then
release the lever.
Fore-aft adjustment: 160 mm (6.3 in)

Adjusting seat cushion

Turn the knob (2) to adjust the cushion to the desired strength.

Adjusting reclining angle

Pull up lever (3), set the seatback to the desired position, then
release the lever.

SEAT BELT
WARNING
Before fastening the seat belt, check that there is no abnormality in the securing brackets or belt. If there is any wear or
damage, replace.
Even if there appears to be no abnormality in the seat belt, replace the seat belt once every 3 years. The date of manufacture
is woven on the reverse side of the belt.
Adjust and fasten the seat belt before operating the machine.
Always use the seat belt when operating the machine.
Do not use the seat belt with either half of the belt twisted.

Check that the bolts of the clamp securing the belt to the chassis are not loose. Tighten them if they are loose.
The tightening torque for the mounting bolt is 24.5 ± 4.9 N·m (2.5 ± 0.5 kgf·m, 18.1 ± 3.6 lbft).
If the belt surface is scratched or frayed or if the fittings are broken or deformed, replace the seat belt unit.

6-4
.

ATTACHMENTS, OPTIONS SUSPENSION SEAT

FASTENING AND REMOVING

1. After adjusting the seat position, adjust tether belt (1). Tense
the tether belt and install it when there is no one sitting on the
seat.
2. Sit on the seat, hold buckle (2) and tongue (3) with your left and
right hands, insert tongue (3) into buckle (2), then pull the belt
to check that it is securely locked.
3. When removing the belt, raise the tip of buckle (2) lever to
release it.

SEAT BELT ADJUSTMENT

SHORTENING
Pull the free end of the belt on either the buckle body or tongue
side.

LENGTHENING
Pull the belt while holding it at a right angle to the buckle or tongue.

6-5
.
.

INDEX

INDEX

<C> <L>
CHECK AFTER FINISHING WORK 3- 53 LIFTING MACHINE 3- 65
CHECK BEFORE STARTING ENGINE, LOADING, UNLOADING WORK 3- 62
ADJUST 3- 19 LOCKING 3- 53
COLD WEATHER OPERATION 3- 66 LONG-TERM STORAGE 3- 69
AFTER COLD WEATHER 3- 68 AFTER STORAGE 3- 69
AFTER COMPLETION OF WORK 3- 68 BEFORE STORAGE 3- 69
PRECAUTIONS FOR LOW DURING STORAGE 3- 69
TEMPERATURE 3- 66
CONTROL LEVERS AND PEDALS 3- 12 <M>
MACHINE OPERATION 3- 38
<D> MAINTENANCE SCHEDULE CHART 4- 14
DECELERATOR PEDAL 6- 3 MAINTENANCE SCHEDULE CHART 4- 14
DOOR POCKET 3- 18
<N>
<E> NECESSARY INFORMATION 1- 8
EMISSION CONTROL INFORMATION
LABEL 1- 9 <O>
ENGINE SERIAL NO. PLATE 1- 8 OPERATION 3- 19
EXPLANATION OF COMPONENTS 3- 4 OPERATIONS AND CHECKS AFTER
STARTING ENGINE 3- 35
<F> OUTLINE OF OIL, FUEL, COOLANT,
FORWORD 1- 2 AND PERFORMING OIL CLINIC 4- 4
FRONT PANEL 3- 4 OUTLINE OF SERVICE 4- 4
FRONT/REAR, LEFT/RIGHT
DIRECTIONS OF MACHINE 1- 7 <P>
FUSE 3- 18 PARKING MACHINE 3- 51
PERIODIC REPLACEMENT OF SAFETY
<G> CRITICAL PARTS 4- 13
GENERAL PRECAUTIONS 2- 8 POSITIONF OF SERVICE METER 1- 9
GENERAL PRECAUTIONS 6- 2 PRECAUTIONS FOR MAINTENANCE 2- 26
PRECAUTIONS RELATED TO PRECAUTIONS FOR OPERATION 2- 16
SAFETY 6- 2 BATTERY 2- 23
GENERAL VIEW 3- 2 OPERATION 2- 18
GENERAL VIEW OF CONTROLS AND STARTING ENGINE 2- 16
GAUGES 3- 3 TOWING 2- 25
GENERAL VIEW OF MACHINE 3- 2 TRANSPORTATION 2- 22
GUIDE TO MAINTENANCE 4- 2 PRECAUTIONS FOR OPERATION 3- 48
PRODUCT IDENTIFICATION NUMBER
<H> (PIN)/MACHINE SERIAL NO. PLATE 1- 8
HANDLING RUBBER SHOES (RUBBER
SHOES ONLY) 3- 57 <R>
RELATING TO ELECTRIC SYSTEM 4- 6
<I>
INTRODUCTION 1- 7 <S>
SAFETY 2- 2
SAFETY CRITICAL PARTS 4- 13

7-1
.

INDEX

SAFETY INFORMATION 1- 5 <W>

SAFETY LABELS 2- 4 WEAR PARTS LIST 4- 7
POSITIONS OF SAFETY WEAR PARTS LIST 4- 7
PICTOGRAMS 2- 4 WORK POSSIBLE USING BULLDOZER 3- 49
SAFETY LABELS 2- 5
SERVICE PROCEDURE 4- 16
EVERY 1000 HOURS SERVICE 4- 50
EVERY 2000 HOURS SERVICE 4- 55
EVERY 250 HOURS SERVICE 4- 40
EVERY 4000 HOURS SERVICE 4- 56
EVERY 50 HOURS SERVICE 4- 39
EVERY 500 HOURS SERVICE 4- 46
INITIAL 250 HOURS SERVICE(ONLY
AFTER THE FIRST 250 HOURS) 4- 16
WHEN REQUIRED 4- 17
SHIFTING BETWEEN FORWARD AND
REVERSE 3- 43
SHIFTING GEAR 3- 42
SPECIFICATIONS 5- 2
STANDARD TIGHTENING TORQUES
FOR BOLTS AND NUTS 4- 12
STARTING ENGINE 3- 32
STEERING MACHINE 3- 44
STOPPING ENGINE 3- 37
SUSPENSION SEAT 6- 4
ADJUSTMENT 6- 4
SEAT BELT 6- 4
SWITCHES 3- 10

<T>
TABLE TO ENTER SERIAL NO. AND
DISTRIBUTOR 1- 10
TIPS FOR LONGER UNDERCARRIAGE
LIFE 3- 54
TRANSPORTATION 3- 62
TRANSPORTATION MEANS 3- 62
TROUBLESHOOTING 3- 70
AFTER RUNNING OUT OF FUEL 3- 70
IF BATTERY IS DISCHARGED 3- 71
MACHINE TOWING METHOD 3- 70
OTHER TROUBLE 3- 75
TORQUE LIST 4- 12

<U>
USE OF FUEL, COOLANT AND
LUBRICANTS ACCORDING TO
AMBIENT TEMPERATURE 4- 8
PROPER SELECTION OF FUEL,
COOLANT AND LUBRICANTS 4- 8

7-2
.
.

D21A-8, D21P-8 GALEO BULLDOZER

Form No. SEAM057800T

©
2003 KOMATSU
All Rights Reserved
Printed in Japan 09-03