Komatsu D37PX-21 User Manual

EEAM024300

Operation &
Maintenance Manual

D31EX, PX-21
D37EX, PX-21
D39EX, PX-21

BULLDOZER

SERIAL NUMBER

D31EX-21 - 50501 and up
D31PX-21 - 50501 and up
D37EX-21 - 5709 and up
D37PX-21 - 5709 and up
D39EX-21 -1501 and up
D39PX-21 -1501 and up

WARNING

Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.

FOREWORD

11

FOREWORD FOREWORD

FOREWORD 1

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 acciden ts
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machi nes. Acci­dents can be prevented by knowing beforehand conditio ns that may cause a haz ard when performing op eration
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 manu al carefully so that they shou ld 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, immediat ely 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 internationa l standard units (SI). For the reference pur­pose, weight units used in the p ast are also displayed in { }.

Storage location for the Operation and Maintenance
Manual:

If machine is equipped without cab.
Pocket at rear of operator's seat

If machine is equipped with a cab.
Pocket at rear of operator's seat
Inside of right and left doors

1-2

FOREWORD SAFETY INFORMATION

SAFETY INFORMATION 1

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.

DANGER

WARNING

CAUTION

Example of safety message using signal word

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 d eath
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.

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 n ot locked, this may ca use a serious inju ry or
death.

Other signal words

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

NOTICE
REMARK

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

This gives information that is useful to know.

1-3

SAFETY INFORMATION FOREWORD

q 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 pr ocedur es.

Example of safety label using words

Safety labels using pictogram

Part No.

Safety pictograms use a picture to expre ss 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.

Part No

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintena nce.
Therefore, the safety messages in this manual and on the machine may not include all po ssible 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))

1-4

FOREWORD SAFETY INFORMATION

Noise emission levels (D37EX, D37PX)

Two labels ind icating the machine noise level a re affixed on the
machine.

q Sound pressure level at the operator’s station, measured

according to ISO6396 (Dynamic test method, simulated
working cycle).

q Sound power level emitted by the machine, measured

according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.

Vibration levels (D37EX, D37PX)

When used for its intended purpose, levels of vibratio n for the
earth-moving machine transmitted from the operator’s seat are
lower than or equal to the tested vibrations for the relative
machinery class in compliance with ISO 7096.

The actual acceleration value for the hands and arms is less
than or equal to 2.5 m/s². The actual acceleration value for the
body is less than or equal to 0.5 m/s².

These values were determined using a representative machine
and measured during the typical operating condition indicated
below according to the measurement procedures that are
defined in the standards ISO 2631/1 and ISO 5349.

1-5

SAFETY INFORMATION FOREWORD

Operating condition:

(WHEEL LOADER:) V-shape loading
( H Y DR A U LI C E XC AVAT O RS:) E x cav a t in g ( Dig g i ng- l oading-

rotating-unloading-rotating)
(TRACTOR DOZER:) Dozing and spreading material through

forward/reversing motion
(Rigid/Articulate dumper:) Work cycle (including waiting, travel-

ling, loading, travelling with load, unloading, and travelling with­out load)

Guide to Reduce Vibration Levels on Machine

The following guides can help an operator of this machine to
reduce the whole body vibration levels:

1. Use the correct equipment and attachments.

2. Maintain the machine according to this manual
q Tire pressures (for wheeled machines), tension of

crawler (for crawler machines)

q Brake and steering systems
q Controls, hydraulic system and linkages

3. Keep the terrain where the machine is working and travel­ing in good condition

q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with

machine and schedule time to maintain terrain condi­tions

4. Use a seat that meets ISO 7096 and keep the seat main­tained and adjusted

q Adjust the seat and suspension for the weight and size

of the operator

q Wear seat belt
q Inspect and maintain the seat suspension and adjust-

ment mechanisms

5. Steer, brake, accelerate, shift gears (for wheeled
machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly

1-6

FOREWORD SAFETY INFORMATION

6. Adjust the machine speed and travel path to minimize the
vibration level

q When pushing with bucket or blade, avoid sudden

loading; load gradually

q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over roug h ter-

rain

q Make the curve radius of traveling path as large as

possible

q Travel at low speed when traveling around sharp

curves

7. Minimize vibrations for long work cycle or long distance
traveling

q Reduce speed to prevent bounce
q Transport machines long distances between worksites

8. The following guidelines can be effective to m inimize risks
of low back pain

q Operate the machine only when you are in good

health.

q Provide breaks to reduce long periods of sitting in the

same posture

q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads

1-7

INTRODUCTION FOREWORD

INTRODUCTION 1

This Komatsu machine is designed to be used mainly for the following work:

q Dozing
q Smoothing
q Cutting into hard or frozen ground or ditching

See the section “WORK POSSIBLE USING BULLDOZER (3-95)“ for further details.

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1

Front

Left

Operator’s seat

Rear

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.

Right

Sprocket

1-8

FOREWORD NECESSARY INFORMATION

NECESSARY INFORMATION 1

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

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1

This is at the front bottom right of the oper ator's seat.
The design of the nameplate differs according to the territory.

ENGINE SERIAL NO. PLATE 1

This is at the front top of the engine on the left side machine.

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

1-9

NECESSARY INFORMATION FOREWORD

POSITION OF SERVICE METER 1

The service meter is provided at the lower part of the monitor
panel.

TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN 1

Machine serial No.

Engine serial No.

Product Identification Number

Manufacturers name:
Address:

Distributor
Address

Phone
Service personnel for your

machine:

KOMATSU LTD.
3-6 Akasaka
Minato-ku, 101 Tokyo
Japan

1-10

FOREWORD NECESSARY INFORMATION

MACHINE SERIAL PLATE.

Model

Seriel Number

Manufacturing year

Weight

Engine power

Product Identification Number

Manufacturer

kg
kW

1-11

CONTENTS

CONTENTS

FOREWORD

FOREWORD.........................................................................................................................................................1-2

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

Noise emission levels (D37EX, D37PX) .....................................................................................................1-5

Vibration levels (D37EX, D37PX) ...............................................................................................................1-5

GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............................................................1-6

INTRODUCTION................................................................................................................................................... 1-8

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.......................................................................1-8

NECESSARY INFORMATION .............................................................................................................................1-9

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................................ 1-9

ENGINE SERIAL NO. PLATE.....................................................................................................................1-9

POSITION OF SERVICE METER ............................................................................................................ 1-10

TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN..........................................................................1-10

MACHINE SERIAL PLATE. ...................................................................................................................... 1-11

SAFETY

SAFETY................................................................................................................................................................2-2

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

POSITIONS OF SAFETY PICTOGRAMS ..................................................................................................2-4

SAFETY LABELS ........ ... ... .... ... ... ... .... ...................................... .... ...................................... ........................2-5

GENERAL PRECAUTIONS ...............................................................................................................................2-10

PRECAUTIONS FOR OPERATION...................................................................................................................2-19

STARTING ENGINE................................................................................................................................. 2-19

OPERATION.............................................................................................................................................2-21

TRANSPORTATION................................................................................................................................. 2-24

BATTERY ................................................................................................................................................. 2-25

TOWING ...................................................................................................................................................2-27

PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-28

1-12

CONTENTS

OPERATION

GENERAL VIEW .................................................................................................................................................. 3-2

GENERAL VIEW OF MACHINE..................................... ... .... ... ... ... .... ... ... ....................................... ........... 3-2

GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3

EXPLANATION OF COMPONENTS.................................................................................................................... 3-5

FRONT PANEL........................................................................................................................................... 3-5

CHECK MONITOR SYSTEM ............................................................................................................3-6

EMERGENCY CAUTION ITEMS ...................................................................................................... 3-7

CAUTION CAUTION ITEMS .............................................................................................................3-9

METER GROUP.... ... ... ... .... ... ... ....................................... ... ... .... ...................................... ... ............. 3-11

LAMPS............................................................................................................................................. 3-20

METHOD OF USING MAINTENANCE MODE................................................................................ 3-21

SWITCHES............................................................................................................................................... 3-30

CONTROL LEVERS AND PEDALS ......................................................................................................... 3-35

FUSE ........................................................................................................................................................ 3-41

ELECTRIC POWER TAKE-OUT ADAPTER ............................................................................................ 3-42

DOOR - OPEN LOCK............................................................................................................................... 3-43

SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-43

CAP, COVER WITH LOCK....................................................................................................................... 3-44

METHOD OF OPENING AND CLOSING CAP WITH LOCK ............................. .... ... ... ... ... .... ... ... ... 3-44

METHOD OF OPENING AND CLOSING COVER WITH LOCK..................................................... 3-45

DOOR POCKET ....................................................................................................................................... 3-45

ASHTRAY................................................................................................................................................. 3-46

LUNCHBOX HOLDER BELT.................................................................................................................... 3-46

CUP HOLDER .......................................................................................................................................... 3-46

TOOL BOX................................................................................................................................................ 3-47

GREASE PUMP HOLDER........................................................................................................................ 3-47

CAR STEREO, HANDLING...................................................................................................................... 3-48

EXPLANATION OF COMPONENTS............................................................................................... 3-48

METOD OF OPERATION................................................................................................................ 3-53

PRECAUTION WHEN USING......................... ... ... ... .... ...................................... .... ... ... ... ... .... ... ... ... 3-55

AIR CONDITIONER, HANDLING ............................................................................................................. 3-56

EXPLANATION OF PARTS............................................................................................................. 3-56

PREVENTION METHOD OF ENTRY OF DUST............................................................................. 3-58

PRECAUTION WHEN USING AIR CONDITIONER........................................................................ 3-58

INSPECTION DURING OFF-SEASON........................................................................................... 3-58

PROCEDURE FOR REPLACING RECEIVER................................................................................ 3-59

CLEANING AIR FILTER.................................................................................................................. 3-59

ACCUMULATOR, HANDLING.................................................................................................................. 3-60

METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH

ACCUMULATOR............................................................................................................................. 3-60

OPERATION....................................................................................................................................................... 3-61

CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-61

WALK-AROUND CHECK ................................................................................................................ 3-61

CHECK BEFORE STARTING............................................ ... .... ... ... ... ... .... ... ... ... .... ......................... 3-63

1-13

CONTENTS

ADJUSTMENT.................................................................................................................................3-72

OPERATION AND CHECK BEFORE STARTING ENGINE............................................................3-75

STARTING ENGINE................................................................................................................................. 3-77

NORMAL STARTING ...................................... ... .... ... ... ... .... ... ... ....................................... ... ... ......... 3-77

STARTING IN COLD WEATHER....................................................................................................3-79

OPERATIONS AND CHECKS AFTER STARTING ENGINE................................................................... 3-81

BREAKING IN THE NEW MACHINE ..............................................................................................3-81

WARMING UP OPERATIONS ............... ...................................... .... ... ... ... ... .... ... ... ... .... ... ...............3-81

STARTING IN COLD WEATHER....................................................................................................3-82

STOPPING ENGINE . ... ... ... ....................................... ... .... ... ....................................... ... ... ... .... ..................3-84

MACHINE OPERATION ........................................................................................................................... 3-85

MOVING MACHINE................................................................... ... ....................................... ... ......... 3-85

STOPPING MACHINE..................................................................................................................... 3-88

SHIFTING GEARS....................................................................................................................................3-89

SHIFTING BETWEEN FORWARD AND REVERSE ................................................................................3-90

STEERING MACHINE.............................................................................................................................. 3-91

NORMAL TURNING............................................... ... ....................................... ... ... .........................3-91

TURNING WHILE DESCENDING A SLOPE............................. ... .... ... .......................................... .. 3-92

PRECAUTIONS FOR OPERATION ......................................................................................................... 3-93

PAY ATTENTION TO GAUGES......................................................................................................3-93

PERMISSIBLE WATER DEPTH...................................................................................................... 3-93

METHOD OF USING BRAKES .......................................................................................................3-93

PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS..........................................................3-93

PRECAUTIONS ON SLOPES.........................................................................................................3-94

IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS................................... 3-94

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

OBSTRUCT THE VIEW.................................................................................................................. 3-94

PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY..................................................... 3-94

WORK POSSIBLE USING BULLDOZER .................................................................................................3-95

DOZING........................................................................................................................................... 3-95

SMOOTHING...................................................................................................................................3-95

CUTTING INTO HARD OR FROZEN GROUND OR DITCHING.................................................... 3-96

FELLING TREES, REMOVING STUMPS ....................................................................................... 3-96

SIDE-CUTTING OPERATIONS....................................................................................................... 3-96

PARKING MACHINE ....................................... ... ....................................... ... ............................................ 3-97

CHECK AFTER FINISHING WORK ...................................... ... .... ... ... ... .... ... ... ... ... ................................... 3-98

BEFORE STARTING ENGINE........................................................................................................ 3-98

AFTER STARTING ENGINE...........................................................................................................3-98

LOCKING..................................................................................................................................................3-99

TIPS FOR LONGER UNDERCARRIAGE LIFE ...................................................................................... 3-100

OPERATION METHOD.................................................................................................................3-100

INSPECTION AND ADJUSTMENT...............................................................................................3-100

INSPECTION AND REPAIR.......................................................................................................... 3-101

TRANSPORTATION......................................................................................................................................... 3-103

TRANSPORTATION MEANS.................................................................................................................3-103

PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................... 3-103

REMOVING CAB................... ... ... ... .... ... ... ....................................... ... ... .... ............................................. 3-103

1-14

CONTENTS

LOADING, UNLOADING WORK.... ... ....................................... ... ... .... ... ... ... ... .... ... ... ... ........................... 3-104

LIFTING MACHINE................................................................................................................................. 3-108

COLD WEATHER OPERATION...................................................................................................................... 3-109

PRECAUTIONS FOR LOW TEMPERATURE............................. ... .... ... ... ... ... .... ... ... ... .... ... ... ................. 3-109

AFTER COMPLETION OF WORK......................................................................................................... 3-111

AFTER COLD WEATHER...................................................................................................................... 3-111

LONG-TERM STORAGE..................................................................................................................................3-112

BEFORE STORAGE............................................................................................................................... 3-112

DURING STORAGE............................................................................................................................... 3-112

AFTER STORAGE.................................................................................................................................. 3-112

TROUBLESHOOTING...................................................................................................................................... 3-113

AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-113

MACHINE TOWING METHOD............................. .... ... ... ... ....................................... ... .... ... .................... 3-113

WHEN IT IS POSSIBLE TO START ENGINE.............................. ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... . 3-114

WHEN ENGINE DOES NOT START ................................. ... .... ... ... ... ... ........................................ 3-115

IF BATTERY IS DISCHARGED.............................................................................................................. 3-120

REMOVE AND INSTALL BATTERY ............................... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... ........... 3-121

PRECAUTIONS FOR BATTERY CHARGING .............................................................................. 3-121

STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-122

WHEN ENGINE DOES NOT STOP........................................................................................................ 3-124

OTHER TROUBLE ................................................................................................................................. 3-125

ELECTRICAL SYSTEM................................................................................................................. 3-125

MONITOR PANEL......................................................................................................................... 3-126

CHASSIS....................................................................................................................................... 3-127

ENGINE......................................................................................................................................... 3-128

MAINTENANCE

GUIDE TO MAINTENANCE................................................................................................................................. 4-2

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

OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5

OIL..................................................................................................................................................... 4-5

FUEL.................................................................................................................................................. 4-5

COOLANT ......................................................................................................................................... 4-6

GREASE............................................................................................................................................ 4-6

CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)......................................................... 4-6

STORING OIL AND FUEL................................................................................................................. 4-7

FILTERS............................................................................................................................................ 4-7

RELATING TO ELECTRIC SYSTEM ......................................................................................................... 4-8

WEAR PARTS LIST............................................................................................................................................. 4-9

WEAR PARTS LIST.................................................................................................................................... 4-9

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .................... 4-11

1-15

CONTENTS

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS .........................................................4-11

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....................................................................4-15

TORQUE LIST.......................................................................................................................................... 4-15

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ..........................................................................4-16

SAFETY CRITICAL PARTS................................... ... ... ....................................... ... .... ... ... ... .... ... ...............4-16

MAINTENANCE SCHEDULE CHART ...............................................................................................................4-17

MAINTENANCE SCHEDULE CHART......................................................................................................4-17

WHEN REQUIRED.......................................................................................................................... 4-17

CHECK BEFORE STARTING ......................................................................................................... 4-17

EVERY 50 HOURS SERVICE................... ......................................................................................4-17

EVERY 250 HOURS SERVICE....................................................................................................... 4-17

EVERY 500 HOURS SERVICE....................................................................................................... 4-17

EVERY 1000 HOURS SERVICE.....................................................................................................4-17

EVERY 2000 HOURS SERVICE.....................................................................................................4-18

EVERY 4000 HOURS SERVICE.....................................................................................................4-18

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

WHEN REQUIRED................ ... ....................................... ... ... ... ....................................... ... .... ..................4-19

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT......................................................... 4-19

CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-23

CHECK TRACK SHOE TENSION, ADJUST...................................................................................4-25

CHECK AND TIGHTEN TRACK SHOE BOLTS..............................................................................4-27

CHECK ELECTRICAL INTAKE AIR HEATER ................................................................................ 4-27

REVERSE AND REPLACE END BITS AND CUTTING EDGES..................................................... 4-28

CHECK IDLER OIL LEVEL, ADD OIL ............................................................................................. 4-29

ADJUST IDLER CLEARANCE ............................................... ... ... .... ... ...................................... .... .. 4-29

ADJUST PLAY IN CENTER BALL ..................................................................................................4-30

GREASE DOOR HINGE..................................................................................................................4-30

CHECK DOOR LOCK STRIKER..................................................................................................... 4-31

CHECK, ADJUST AIR CONDITIONER ........................................................................................... 4-31

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................................. 4-33

REPLACE WIPER BLADE ........................ ... ....................................... ... ... ... .... ... ... ... .... ... ... ... .........4-33

PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM.....................................................4-34

PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM................. 4-35

CHECK BEFORE STARTING ............... ... ... .... ... ... ... ... .... ... ... ... ....................................... ... .... ... ... ... ......... 4-36

EVERY 50 HOURS SERVICE..................................................................................................................4-37

DRAIN WATER, SEDIMENT FROM FUEL TANK...........................................................................4-37

EVERY 250 HOURS SERVICE................................................................................................................ 4-38

LUBRICATING.................................................................................................................................4-38

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ..................................................................4-40

CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-41

CHECK BRAKE PERFORMANCE..................................................................................................4-43

CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)............................................4-44

EVERY 500 HOURS SERVICE................................................................................................................ 4-45

REPLACE FUEL FILTER CARTRIDGE ....................................... .... ... ... ... ... .... ... ... ... .... ..................4-45

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....................4-48

1-16

CONTENTS

REPLACE CORROSION RESISTOR CARTRIDGE ....................................................................... 4-49

CLEAN, CHECK RADIATOR FINS AND OIL COOLER FINS......................................................... 4-50

EVERY 1000 HOURS SERVICE.............................................................................................................. 4-51

CHANGE OIL IN FINAL DRIVE CASE............................................................................................ 4-51

CHECK FAN BELT TENSION, ADJUST......................................................................................... 4-51

CHECK ALL TIGHTENING PARTS OF TURBOCHARGER........................................................... 4-51

CHECK PLAY OF TURBOCHARGER ROTOR ................. ... .... ... ... ... ... .... ... ... ... .... ......................... 4-52

CHECK FOR LOOSE ROPS MOUNT BOLTS................................................................................ 4-52

EVERY 2000 HOURS SERVICE.............................................................................................................. 4-53

CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION

STRAINER....................................................................................................................................... 4-53

CLEAN, CHECK TURBOCHARGER............................................................................................... 4-55

CHECK VIBRATION DAMPER ................................ .... ...................................... .... ... ... ... ... .... ... ... ... 4-55

CHECK ALTERNATOR, STARTING MOTOR .......................... ......................................... .... ... ... ... 4-55

CHECK ENGINE VALVE CLEARANCE, ADJUST.......................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... 4-55

EVERY 4000 HOURS SERVICE.............................................................................................................. 4-56

CHECK WATER PUMP................................... ... ....................................... ... ... ... .... ... ... ... ... .... ... ...... 4-56

SPECIFICATIONS

SPECIFICATIONS................................................................................................................................................ 5-2

ATTACHMENTS, OPTIONS

GENERAL PRECAUTIONS ................................................................................................................................. 6-2

PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2

HANDLING HYDRAULIC RIPPER....................................................................................................................... 6-3

GENERAL VIEW............................................................. ... .... ... ... ....................................... ........................ 6-3

EXPLANATION OF COMPONENTS.......................................................................................................... 6-4

OPERATION............................................................................................................................................... 6-5

CHECK BEFORE STARTING ENGINE, ADJUST ............................. ... .... ... ... ... .... ... ... ... ... .... ... ... ... .. 6-5

PRECAUTIONS WHEN OPERATING............................................................................................... 6-5

ADUSTING POSTURE OF WORK EQUIPMENT ............................................................................. 6-5

TROUBLESHOOTING................................................................................................................................ 6-6

OTHER TROUBLE...................................... .... ...................................... .... ........................................ 6-6

MAINTENANCE.......................................................................................................................................... 6-6

EVERY 250 HOURS SERVICE.........................................................................................................6-6

DELUXE SEAT..................................................................................................................................................... 6-7

HEADREST .......................................................................................................................................................... 6-9

EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT................................................................................. 6-10

1-17

CONTENTS

INDEX

COLOPHON

1-18

SAFETY

12

WARNING

Please be sure that you fully underst an d this manual an d the
precautions discribed in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precaustions strictly.

SAFETY SAFETY

SAFETY 2

SAFETY LABELS................................................................................................................................................ 2-42

POSITION OF SAFETY PICTOGRAMS......................................................................................................2-42

SAFETY LABELS.........................................................................................................................................2-52

GENERAL PRECAUTIONS

Safety rules................................................................................................................................................2-102

If abnormalities are found................................ .... ... ... ... ... .... ... ... ... .... ... .......................................................2-102

Clothing and personal protective items......................................................................................................2-102

Fire extinguisher and first aid kit ................................................................................................................2-102

Safety features...........................................................................................................................................2-112

Keep machine clean................................................................................................................................... 2-112

Inside operator's compertment................................................................................................................... 2-112

Always apply lock when leaving operator's seat........................................................................................ 2-112

Handrails and steps ...................................................................................... ... ... ... ... .... ... ..........................2-122

Mounting and dismounting......................................................................................................................... 2-132

No people on attachment........................................................................................................................... 2-132

Crushing or cutting prevention...................................................................................................................2-132

Prevention of burns....................................................................................................................................2-132

Fire prevention...........................................................................................................................................2-142

Action if fire occurs.....................................................................................................................................2-152

Window washer liquid ................................................................................................................................2-152

Precautions when using ROPS (Roll Over Protective Structure).................................. ... ... ... .... ... ... ... ... .... 2-152

Precautions for attachments ........................................... .... ... ... ... .... ..........................................................2-152

Unauthorized medification..........................................................................................................................2-152

Safety at worksite....................................................................................................................................... 2-162

Working on loose ground........................................................................................................................... 2-162

Do not go close to high-voltage cables ......................................................................................................2-162

Ensure good visibility .................................................................................................................................2-172

Ventilation for enclosed aresa.................................................................................................................... 2-172

Checking signalman's signals and signs.................................................................................................... 2-172

Emergency exit from operator's cab ..........................................................................................................2-172

Be careful about asbestos dust..................................................................................................................2-182

PRECAUTIONS FOR OPERATIONS............................................................................................................... 2-192

STARTING ENGINE..................................................................................................................................2-192

Checks before starting engine ............................................................................................................2-192

Precautions when starting.................. ... ... .... ... ... ... ... .... ... ... ... .... ... .......................................................2-192

Precautions in cold areas.................................................................................................................... 2-202

OPERATION.............................................................................................................................................. 2-212

Checks before operation.....................................................................................................................2-212

Precautions for moving machine forward or in reverse.......................................................................2-212

Precautions when traveling...................... .... ... ... ... ... .... ... ... ... ....................................... ... ....................2-212

Traveling on slopes............................................................................................................................. 2-222

Using brakes............................... .... ... ....................................... ... .......................................................2-222

Operate carefully on snow ..................................................................................................................2-232

Parking machine...... ... ... .... ... ... ... .... ... ... ....................................... ... ... .... ... ... ... .................................... 2-232

TRANSPORTATION..................................................................................................................................2-242

Loading and unloading........................................................................................................................2-242

Shipping.............................................................................................................................................. 2-242

BATTERY...................................................................................................................................................2-252

Battery hazard prevention..................... ... .... ... ... ... ... .... ...................................... .... ... ... ... ....................2-252

Starting with booster cable.................................................................................................................. 2-262

TOWING .................................................................................................................................................... 2-272

When towing ....................................................................................................................................... 2-272

2-2

SAFETY SAFETY

PRECAUTIONS FOR MAINTENANCE ............................................................................................................2-282

Warning tag................................................................................................................................................ 2-282

Keep work place clean and tidy............... .... ... ... ... ... .... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... .................... 2-282

Appoint leader when working with others .................................................................................................. 2-282

Stop engine before carrying out inspection and maintenance................................................................... 2-282

Two workers for maintenance when engine is running.............................................................................. 2-292

Proper tools........................ ...................................... .... ... ... ... ..................................................................... 2-302

No unauthorized personnel into area......................................................................................................... 2-302

Attachments............................................................................................................................................... 2-302

Work under the machine.................................... ....................................... ... ... ... .... ... ... ... .... ....................... 2-312

Noise.......................................................................................................................................................... 2-312

Precautions when using hammer............................................................................................................... 2-312

Repair welding........................................................................................................................................... 2-312

Removing battery terminal.... ... ... .... .......................................... .......................................... ....................... 2-312

Precautions when Using high-pressure grease to adjust track tension ..................................................... 2-322

Do not disassemble recoil spring............................................................................................................... 2-322

Precaution with high-pressure oil............................................................................................................... 2-322

Handling high-pressure hoses ................................................................................................................... 2-332

Waste material........................................................................................................................................... 2-332

Maintenance for air conditioner.................................................................................................................. 2-332

Compressed air.......................................................................................................................................... 2-332

Periodic replacement of safety critical parts .............................................................................................. 2-332

2-3

SAFETY LABELS SAFETY

SAFETY LABELS 2

The following warning signes and safety labels are used on this machine.

q Be sure that you fully understand the correct position and content of labels.
q 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.

q There are also other labels in addition to the warning signes and safety labels. Handle those labels in the

same way.

q If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the p art

numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.

POSITIONS OF SAFETY PICTOGRAMS 2

2-4

SAFETY SAFETY LABELS

SAFETY LABELS 2

(1) Caution before operating machine (09651-A0481)

q Warning!

q Read manual before operation, maintaince, disassembly,

assembly and transportation.

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

WARNING

To prevents SEVERE INJURY or DEATH, do the following
before moving machine or its attachments:

q Honk horn to alert people nearby.
q Be sure no one is on or near the machine.
q Use spotter if view is obstructed.

Follow above even if the machine is equipped with back­up alarm and mirrors.

(3) Caution for leaving operator's seat (09654-B0481)
q Sign indicates a hazard of unexpected m oving of stopped

machine.

q Lower working device to ground, move safety lever to lock

position and take engine key with you before leaving
machine.

2-5

SAFETY LABELS SAFETY

(4) Caution with high-temperature coolant, hydraulic oil
(09653-A0481)
q Never remove the cap when the engine is at operating

(high) temperature. Stream or high temperature oil blowing
up from the radiator or hydraulic tank, will cause personal
injury and or burns.

q Never remove the radiator or hydraulic tank oil filler when

cooling water or hydraulic oil is at high temperatures.

(5) Caution for accumulator (09659-A057B) (If equipped)

q There is the hazard of explotion causing injury.
q Do not disassemble the accumulator, make holes in it, cut

it, hit it roll it or bring it near flame.

(6) Caution for adjusting track tension (09657-A0881)
The safety label is attached to the rear side of the track adjust-

ment window cover.
q Sign indicates a hazard or flining plug from track adjuster

that could cause injury.

q Read the manual and adjusting track for safe and proper

handling.

(7) Caution for battery cable (09808-A0881)

q Sing indicates an electric hazard from handling the cable.
q Read the manual for save and proper hand lin g.

2-6

SAFETY SAFETY LABELS

(8) Caution for battery (This plate is stick on the machine by the
battery maker)

DANGER/POISON
EXPLOSIVE GASES
Cigarettes, flames or sparks could cause battery to explode.

Always shield eyes and face from battery.
Do not charge or use booster cables or adjust post connections

without order instruction and training.
KEEP VENT CAPS TIGHT AND LEVEL POISON causes

severe burns contains sulfuric acid in event of accident flush
with water and call a physician immediately.

KEEP OUT OF REACH OF CHILDREN

(9) Caution for engine running (09667-A0481)

q Sign indicates a hazard of rotating parts, such as belt.

q Turn off before inspection and maintenance.

(10) Caution for approach when machine moving
(09806-B1201)

q Sign indicates a hazard of being run over by moving e quip -

ment.

q Keep a safe distance from equipment when it is moving.

2-7

SAFETY LABELS SAFETY

(11) Caution for ROPS (09620-A2000)
ROPS/FOBS CERTIFICATION
This protective structure complies with the standard provided

that it is properly equipped on the machine which mass is less
than the specified maximum mass.

MODEL MACHINE MODEL FOPS LEVEL No.
SERIAL No. MAX. MASS (kg)

WARNING

q If some modification is applied to the ROPS or FOPS, it

might not enough strength and might not be complied
with the standard. Consult Komatsu distributor before
altering.

q ROPS or FOBS may provide less protection if it has

been structurally damaged or involved roll-over. Con­sult Komatsu distributor in that case.

q Always wear seat belt when moving

(12) Prohibition of jump start (09842-A0481)
q Start the engine only after sitting down in the operator’s

seat.

q 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.

2-8

SAFETY SAFETY LABELS

(13) Caution with high-temperature parts (09817-A0753)
q Sign indicates a burn hazard from touching heated parts,

such as engine, motor, or muffler during or right after oper­ation.

q Never toch when hot.

2-9

GENERAL PRECAUTIONS SAFETY

GENERAL PRECAUTIONS 2

SAFETY RULES

q Only trained and authorized personnel can operate and maintain the machine.
q Follow all safety rules, precautions and instructions when operating or performing maintenance on the

machine.

q 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.

q When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-

stand all hand signals that are to be used.

IF ABNORMALITIES ARE FOUND

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

CLOTHING AND PERSONAL PROTECTIVE ITEMS

q Do not wear loose clothing and accessori es. There is a hazard th at they may catch o n control levers or other

protruding parts.

q 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.

q 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.

q 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.
q Be sure that fire extinguishers have been provided and

read the labels to ensure that you know how to use them in
emergencies.

q Carry out periodic inspection and maintenance to ensure

that the fire extinguisher can always be used.

q Provide a first aid kit at the storage point. Carry out peri-

odic checks and add to the contents if necessary.

2-10

SAFETY GENERAL PRECAUTIONS

SAFETY FEATURES

q Be sure that all guards and covers are in their proper position. Have gu ards and cover s rep aired immedi ately if

they are damaged.

q Understand the method of use of safety features and use them properly.
q Never remove any safety features. Always keep them in good operating condition.

KEEP MACHINE CLEAN

q 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).

q 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

q 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 fo ot ma y slip an d t his m a y ca us e a ser iou s
accident.

q Do not leave parts or tools lying around the operator's compartment.
q Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
q Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
q Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT

q Before standing up from the operator's seat (such as when

adjusting the operator's seat), lowe r the work equipment
completely to the ground, set safety lock lever (1) and
parking lever (2) securely to the LOCK position, then stop
the engine.

If you accidentally touch the levers when they are not
locked, there is a hazard that the machine may suddenly
move and cause serious injury or property damage.

q When leaving the machine, always lower the work equip-

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

Free

Lock

Free

Lock

2-11

GENERAL PRECAUTIONS SAFETY

HANDRAILS AND STEPS

To prevent personal injury caused by slipping or falling off the machine, always do as follows.

D31PX,D37PX,D39PX,D39EX

q Climb up and down from the operator's cab at the machine

front. Use the handrails and steps marked by arrows in the
diagram on the right when getting on and off the machine.

q Do not climb up and down from the operator's cab at the

machine side or at the rear. A handrail marked by arrow (A)
in the diagram is provided to support yourself when refilling
fuel in the fuel tank. Do not use it for getting on and off the
machine.

D31EX,37EX

q Climb up and down from the operator's cab at the machine

side. Use the handrails and steps marked by arrows in the
diagram on the right when getting on and off the machine.

q Do not climb up and down from the operator's cab at the

machine front or at the rear. A handrail marked by arrow
(A) in the diagram is provided to support yourself when
refilling fuel in the fuel tank. Do not use it for getting on and
off the machine.

2-12

SAFETY GENERAL PRECAUTIONS

q 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.

q Do not grip the control levers when getting on or off the

machine.

q Never climb on the engine hood or covers where ther e are

no non-slip pads.

q 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.

q Do not get on or off the machine while holding tools in your hand.

MOUNTING AND DISMOUNTING

q Never jump on or off the machine. Never get on or off a moving machine.
q If the machine starts to mo ve when there is no operator on the machine , do not jump on to the machine a nd try

to stop it.

NO PEOPLE ON ATTACHMENTS

Never let anyone ride on the work equipment, or other att achments. 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

q 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 pos sib le to to uc h th e ra di­ator 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

q 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.

2-13

GENERAL PRECAUTIONS SAFETY

FIRE PREVENTION
q 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:

q Do not smoke or use any flame near fuel or oil.
q Stop the engine be fore refueling.
q Do not leave the machine while adding fuel or oil.
q Tighten all fuel and oil caps securely.
q Do not spill fuel on overheated surfaces or on parts of

the electrical system.

q Use well-ventilated areas for adding or storing oil and

fuel.

q Keep oil and fuel in the determined place and do not

allow unauthorized persons to enter.

q After adding fuel or oil, wipe up any spilled fuel or oil.
q When carrying out grinding or welding work on the

chassis, move any flammable materials to a safe plac e
before starting.

q When washing parts with oil, use a non-flammable oil.

Diesel oil and gasoline may catch fire, so do not use
them.

q Put greasy rags and other flammable materials into a

safe container to maintain safety at the work place.

q Do not weld or use a cutting torch to cut any pipes or

tubes that contain flammable liquids.

q 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.

q Fire coming from electric wiring

Short circuits in the electrical system can cause fire.

q Always keep electric wiring connections clean and securely tightened.
q Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.

Repair or replace any damaged wiring.

q 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.

2-14

SAFETY GENERAL PRECAUTIONS

q Explosion caused by lighting equipment

q 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.

q When taking the electrical power for the ligh ting fr om the machine it self, follow the instructions in this man-

ual.

ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows.

q Turn the start switch OFF to stop the engine.
q 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.

q If ROPS is installed, do not remove it when operating the

machine.

q ROPS is installed to protect the operator when machine

rolls over. When machine rolls over, ROPS supports its
weight and absorbs its impact energy.

q If ROPS is modified, its strength may be reduced. When

modifying, consult your Komatsu distributor.

q If ROPS is damaged or deformed by falling objects or by rolling over, it s strength will be reduced and it will not

be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the
method of repair.

Even if ROPS is installed, always fasten your seat belt properly when operatin g the machine. If you do not use
your fasten your seat belt properly, it cannot display its effect.

PRECAUTIONS FOR ATTACHMENTS

q When installing optional parts or attachments, there may be problems with safety or legal restrictions. There-

fore contact your Komatsu distributor for advice.

q Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not

be the responsibility of Komatsu.

q When installing and using optional attachments, read the instruction manual for the attachment, and the gen-

eral information related to attachments in this manual.

UNAUTHORIZED MODIFICATION

Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.

q Komatsu will not be responsible for any injuries, accidents, product failures or other property damages result-

ing from modifications made without authorization from Komatsu.

2-15

GENERAL PRECAUTIONS SAFETY

SAFETY AT WORKSITE

Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
q 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.

q 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.

q 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.

q Take action to prevent unauthorized people from approach-

ing the jobsite.
When working on public roads, position flagmen and erect

barriers to ensure the safety of passing traffic and pedestri­ans.

q 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

q 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 vibra tion 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.

q 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.

q 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.

q Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death.
Always maintain a safe distance (see the table on the right)
between the machine and the electric cable. Check with
the local power company about safe operating procedure
before starting operations.

q To prepare for any possible emergencies, wear rubber

shoes and gloves. Lay a rubber sheet on top of the seat,
and be careful not to touch the chassis with any exposed
part of your body.

Voltage of Cables Safety Distance

100 V - 200 V Over 2 m

6,600 V Over 2 m
22,000 V Over 3 m
66,000 V Over 4 m

154,000 V Ove r 5 m
187,000 V Ove r 6 m
275,000 V Ove r 7 m
500,000 V Over 11 m

q Use a signalman to give warning if the machine

approaches too close to the electric cables.

q When carrying out operations near high voltage cables, do

not let anyone come close to the machine.

2-16

SAFETY GENERAL PRECAUTIONS

q If the machine should come too close or touch the electric cable , to prevent electric sh ock, the operato r 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.

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.

q Position a signalman if there are areas at the rear of the machine where the visibility is not good.
q 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.

q 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.
q 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

q 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 fo llow the instructions from the signalman.

q Only one signalman should give signals.
q 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.

2-17

GENERAL PRECAUTIONS SAFETY

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.

q Spray water to keep down the dust when cleaning. Do not

use compressed air for cleaning.

q 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.

q Do not allow other persons to approach durin g the opera-

tion.

q Always observe the rules and re gulations 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.

2-18

SAFETY PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR OPERATION 2

STARTING ENGINE 2

If there is a warning tag hanging from the work equip men t 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.

q Remove all dirt from the surface of the window glass to ensure a good view.
q Remove all dirt from the surface of the lens of the front lamps and working lamps, and check that they light up

correctly.

q 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.

q Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no dam-

age or wear to the seat belt or mounting clamps.

q Check that the gauges work properly, check the angle of the lights and working lamp s, and che ck th at the con-

trol levers are all at the neutral position.

q Adjust the mirror to a position which gives a good view to the rear from the operator's seat.
q Check that there are no persons or obstacles above, below, or in the area around the machine.

PRECAUTIONS WHEN STARTING

q Start and operate the machine only while seated.
q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a seri-

ous bodily injury or fire.

q When starting the engine, sound the horn as a warning.
q Do not allow anyone apart from the operator to ride on the machine.

2-19

PRECAUTIONS FOR OPERATION SAFETY

PRECAUTIONS IN COLD AREAS

q 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.

q 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 dif ferent powe r source, melt the battery electrolyte and ch eck that

there is no leakage of electrolyte before starting.

2-20

SAFETY PRECAUTIONS FOR OPERATION

OPERATION 2

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.

q Always fasten your seat belt.
q Check the operation of travel, steering and brake systems,

and work equipment control system.

q 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.

q If any abnormality is found, carry out repairs immediately.

PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE

q Before travelling, check again that there is no one in the

surrounding area, and that there are no ob s tacles .

q Before travelling, sound the horn to warn people in the

area.

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

machine.

q Check that the back-up alarm (alarm buzzer when machine

travels in reverse) works properly.

q Fix the operator's compartment doors and windows in posi-

tion securely.

q 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 TRA VELING

q When traveling on level ground, keep the work equipment

at a height of 40 to 50 cm from the ground.

q 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.

2-21

PRECAUTIONS FOR OPERATION SAFETY

q Avoid traveling over obstacles when possible. If the

machine has to travel over an obstacle, keep t he work
equipment close to the ground and travel at low speed.
Never travel over obstacles which make the machine tilt
strongly to one side.

q When traveling or carrying out operations, always keep a

safe distance from people, structures, or other machines to
avoid coming into contact with them.

q 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.

q 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.

q 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.

q When the machine passes over the to p of a hill or when a load is dumped ov er a cliff, the load is suddenly

reduced, and there is danger that the travel speed rises suddenly. To prevent this, lower the travel speed.

q 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.
q Keep the work equipment approx. 20 to 30 cm above the

ground. In case of emergency , lower the work equipment to
the ground immediately to help stop the machine.

q When traveling down a slope, always place the transmis-

sion in low speed and travel down the slope slowly.

q Always travel straight up or down a slope. Traveling at an

angle or across the slope is extremely dangerous.

q 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.

q 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

q Use the deceleration pedal or speed shift switch to adjust the speed. If the brake pedal is suddenly

depressed, the mechanical brake is applied to stop the machine sudde nly, but this is dangerous if the machine
is traveling too fast.

q When traveling downhill, set the travel speed to a low speed and use the engine as a brake.

2-22

SAFETY PRECAUTIONS FOR OPERATION

OPERATE CAREFULLY ON SNOW

q 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.

q With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the

machine to tip over.

q If the machine enters deep snow, the re is a hazard that it may tip over or be come bu rie d in the sn ow. Be care-

ful not to leave the road shoulder or to get trapped in a snow drift.

q When clearing snow, the road shoulder and objects placed beside the road ar e 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.

q When operating on slow-covered slopes, never use the brakes to stop the machine suddenly. Reduce the

speed and use the engine as a brake together with operat ing the brake p edal. If ne cessary, lower the blade to
the ground to stop the machine.

PARKING MACHINE

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

landslides, or of flooding if the land is low.

q Lower the work equipment completely to the ground.

q When leaving the machine, set the steering, directional

and gear shift levers in the N (Neutral) position an d set the
blade lever in the HOLD position, then apply safety lock
lever (1) and parking lever (2) and stop the engine.

q Always close the operator's cab door, and use the key to

lock all the equipment in order to prevent any unauthor ized
person from moving the ma chine . Alwa ys rem ove the key,
take it with you, and leave it in the specified place.

q If it is necessary to park the machine on a slope, a lwa ys do

as follows.
q Set the blade on the downhill side, then dig it into the

ground.

Block

Free

Lock

Free

Lock

q Put blocks under the tracks to prevent the machine

from moving.

Dig it

Block

2-23

PRECAUTIONS FOR OPERATION SAFETY

TRANSPORTATION 2

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.

q Perform loading and unloading on firm, level ground only.

Maintain a safe distance from the edge of the road or cliff.

q 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.

q Be sure the ramp surface is clean and free of grease, oil,

ice and loose materials. Remove dirt from machine-tr acks.
On a rainy day, in particular, be extremely careful since the
ramp surface is slippery.

q Run the engine at low speed and travel slowly.
q When on the ramps, do not touch any other parts.

Ramp

Distance
between ramps

Max 15°C

Blocks

Block

q Never correct your steering on the ramps. If necess ary, drive off the ramps, correct the direction, then enter

the ramps again.

q 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.

q When loading or unloading to an emb ankment or platform, make sure th at it has suitable width, streng th, and

grade.

q For machines equipped with a ca b, always lock the door after boarding th e machine. If this is not done, the

door may suddenly open during transportation.
Refer to “TRANSPORTATION (3-103)“.

SHIPPING

When shipping the machine on a trailer, do as follows.
q The weight, transportation height, and overall length of the machine differ according to the work equipment, so

be sure to confirm the dimensions.

q When passing over bridges or structures on private land, check first that the structu re is stron g enough to sup-

port the weight of the machine. When traveling on public roads, check first with the relevant authorities and fol­low their instructions.

q For details of the shipping procedure, see “TRANSPORTATION (3-103)“ in the OPERA TION section.

2-24

SAFETY PRECAUTIONS FOR OPERATION

BATTERY 2

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.

q 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.

q When working with batteries, always wear safety glasses and rubber gloves.
q Never smoke or use any flame near the battery.

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

the area with large amount of water.

q If acid gets into your eyes, flush them immediately with

large amount of water and seek medical attention.

q 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.
q Do not let tools or other metal objects make any contact betw een the batter y terminals. Do not le ave tools or

other metal objects lying around near the battery.

q 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.

q 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.

q Tighten the battery caps securely.
q Install the battery securely to the determined place.

2-25

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.

q 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).

q When starting from another machine, do not al low the two

machines to touch.

q 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.

q Be sure to connect the positive (+) ca ble first when install-

ing the booster cables. Disconnect the negative (-) cable
(ground side) first when removing them.

q 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.

q Always wear safety goggles and rubber gloves when start-

ing the engine with booster cables.

q 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.

q For details of the starting procedure when using booster

cables, see “STARTING ENGINE WITH BOOSTER
CABLE (3-122)“ in the OPERATION section.

2-26

SAFETY PRECAUTIONS FOR OPERATION

TOWING 2

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 (3 -113)“.

q Always wear leather gloves when handling wire rope.
q Connect a wire rope to the part indicated with the arrow in

the diagram at right.

q During the towing operation, never stand between the tow-

ing machine and the machine being towed.

q Never tow a machine on a slope.
q Never pull the towing equipment up or insert a pedestal.

q 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.

q If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the brake valve sole-

noid, the brake works and the machine cannot move. To move the machine in this case, the oil pressure in the
brake circuit must be heightened to the specified level with a special device. Ask your Komatsu distributor.

2-27

PRECAUTIONS FOR MAINTENANCE SAFETY

PRECAUTIONS FOR MAINTENANCE 2

WARNING TAG

q Always attach the “DO NOT OPERATE“ warning tag to the

work equipment control lever in the operator's cab to alert
others that you are performing service or maintenance on
the machine. Attach additional warning tags around the
machine if necessary.

Warning tag Part No. 09963-A1640
Keep this warning tag in the tool box while it is not used. If

there is not the tool box, keep the tag in the operation m an­ual pocket.

q 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.

STOP ENGINE BEFORE CARRYING OUT INSPENTION AND MAINTENANCE

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

landslides, or of flooding if the land is low.

q Lower the work equipment completely to the ground and

stop the engine.

q Open the engine side cover all the way and ensure that it is

locked open before letting go.

2-28

SAFETY PRECAUTIONS FOR MAINTENANCE

q Set safety lock lever (1) and parking lever (2) to the LOCK

position.

Free

Lock

Free

Lock

q Put blocks under the track to prevent the machine from

moving.

Block

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.

q 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.

q Set safety lock lever (1) and parking lever (2) to the LOCK

position.

q When carrying out operations near the fan, fan belt, or

other rotating parts, there is a hazard of being caught in the

Free

parts, so be careful not to come close.

q Do not touch any control levers. If any control lever must

be operated, give a signal to the other worke rs to warn
them to move to a safe place.

q Never drop or insert tools or other ob jects into the fan or

fan belt. Parts may break or be sent flying.

Lock

Free

Lock

2-29

PRECAUTIONS FOR MAINTENANCE SAFETY

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.

ACCUMULATOR

The accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless procedure may
cause an explosion which could lead to serious injury or prop­erty damage. For this reason, always observe the following
precautions.

q Do not disassemble the accumulator.
q Do not bring it near flame or dispose of it in fire.
q Do not make holes in it, weld it, or use a cutting torch.
q Do not hit or roll the accumulator, or subject it to any

impact.

q When disposing of the accumulator, the gas must be

released. Please contact your Komatsu distributor to have
this work performed.

NO UNAUTHORIZED PERSONNEL INTO AREA

Only authorized personnel can service and repair the machine. Do n ot allow unauthorized personnel into the
area. If necessary, employ an observer.

ATTACHMENTS

q Appoint a leader before starting removal or installation

operations for attachments.

q 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.

2-30

SAFETY PRECAUTIONS FOR MAINTENANCE

WORK UNDER THE MACHINE

q 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.

q 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 th e
machine will suddenly drop. This is extremely dangerous.
Never work under the work equipment or the machine.

NOISE

If the noise from the machine is too loud, it may cause temporary or permanent hearing problems. When carrying
out maintenance of the engine and you are exposed to noise for long pe riods of time, we ar ea r co vers o r ear plugs
while working.

PRECAUTIONS WHEN USING HAMMER

When using a hammer, pins may fly out or metal particles may
be scattered. This may lead to serious injury. Always do as
follows.

q 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.

q When hitting pins or bucket teeth, there is a hazard that

broken pieces might be sent flying an d injure peop le in the
surrounding area. Always check that there is no one in the
surrounding area.

q 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 prop er 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.

2-31

PRECAUTIONS FOR MAINTENANCE SAFETY

PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION

q Grease is pumped into the track tension adjustment sys-

tem under high pressure.
If the specified procedure for maintenance is not followed

when making adjustment, grease drain plug (1) may fly out
and cause serious injury or property damage.

q When loosening grease drain plug (1) to loosen the track

tension, never loosen it more than one turn. Loosen the
grease drain plug slowly.

q 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.

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.

q For the procedure to release internal pressure, see “PROCEDURE FOR RELEASING INTERNAL PRES-

SURE OF HYDRAULIC SYSTEM (4-35)“. Do not inspect or replace any part while internal pressure is
applied.

q 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.

q 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.

2-32

SAFETY PRECAUTIONS FOR MAINTENANCE

HANDLING HIGH-PRESSURE HOSES

q 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.

q Damaged or leaking hydraulic fitting.
q Frayed or cut covering or exposed reinforcement wire layer.
q Covering swollen in places.
q Twisted or crushed movable portion.
q Foreign material embedded in covering.

WASTE MATERIAL

To prevent pollution, pay careful attention to the method of disposing of waste materials.
q 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.

q 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.

COMPRESSED AIR

q When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
q When using compressed air to clean element s or the radi ator, always wear safety goggles, dust mask, gloves,

and other protective equipment.

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

q 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 furthe r 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 (4-

16)“.

q 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.

q Replace or repair safety-critical parts if any defect is found, even when they have not reached the time speci-

fied interval.

2-33

PRECAUTIONS FOR MAINTENANCE SAFETY

2-34

OPERATION

13

WARNING

Please read and make sure that you understand the safety
volume before reading this section.

GENERAL VIEW OPERATION

GENERAL VIEW 3

GENERAL VIEW OF MACHINE 3

Machine equipped with canopy

Machine equipped with cab

(1) Blade (7) Track frame
(2) Angle cylinder (8) Lift cylinder
(3) Radiator mask (9) Idler
(4) Canopy (10) Frame
(5) Track shoe (11) Cab
(6) Sprocket

3-2

OPERATION GENERAL VIEW

GENERAL VIEW OF CONTROLS AND GAUGES 3

(1) Fuel control lever (11 ) Horn switch

Joystick (Steering, directional and gear shift

(2)

lever)
(3) Information switch (13) Brake pedal
(4) Buzzer cancel switch (14) Safety lock lever
(5) Lamp switch (15) Parking lever
(6) Monitor panel (16) Wiper switch (machine equipped with cab)
(7) Reverse travel speed setting switch (17) Room lamp switch (machine equipped with cab)
(8) Shift mode switch
(9) Starting switch
(10) Blade control lever (19) Cigarette lighter (machine equipped with cab)

(12) Decelerator pedal

(18) Wiper motor breaker reset button (machine

equipment with cad)

3-3

GENERAL VIEW OPERATION

MONITOR PANEL

Display panel A (Speed range, Set travel speed,

(1)

Shift mode Indicator)

(9) Filter/oil replacement interval lamp

(2) HST oil temperature gauge (10) Warning lamp
(3) Engine coolant temperature gauge (11) Engine coolant temperature caution lamp
(4) Reverse travel speed indicator (12) Maintenance caution lamp
(5) Fuel level gauge (13) Engine preheating pilot lamp
(6) Charge filter clogging caution lamp (14) Engine oil pressure caution lamp
(7) HST charge pressure caution lamp (15) Battery charge circut caution lamp
(8) HST oil temperature caution lamp (16) Display panel B (Multi-information)

3-4

OPERATION EXPLANATION OF COMPONENTS

EXPLANATION OF COMPONENTS 3

The following is an explanation of the devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand the methods of operat-

ing equipment and meanings of the displays.

FRONT PANEL 3

(A) Emergency caution group (D) Lamp
(B) Caution group (E) Switch
(C) Meter group

3-5

EXPLANATION OF COMPONENTS OPERATION

CHECK MONITOR SYSTEM 3

MONITOR SYSTEM
NOTICE

q Stop the machine on level ground and carry out the monitor check.
q Stop the engine, then turn the st arting switch to the ON position and check that the lamps light up for

approx. 2 seconds. If they do not light up, please ask your Komatsu distributor to carry out inspec­tion.

q The monitor check cannot be carried out until at least 5 seconds has passed after the engine was

stopped.

When carrying out the checks before starting, use the monitor system check.

1. Turn the starting switch to the ON position.

2. Check that the monitor liquid-crystal display and the lamps
all light up for 2 seconds, that the alarm buzzer sounds for
2 seconds, and that “KOMATSU SYSTEM CHECK“ is dis­played for 3 seconds on display panel B (multi-information)
(1).

q After 2 seconds, the current status of the machine is

displayed on liquid-crystal display (2).

q After 2 seconds, the lamp portion (3) goes out.
q After 3 seconds, the operating mode is displayed on

display panel B (multi-information) (1).

REMARK

The following cases do not indicate any abnormality.
When the replacement interval is reached for the oil and filter,
maintenance caution lamp (4) and filter/oil replacement interval
lamp (5) light up or flash for 30 seconds, and the action code is
displayed on display panel B (multi-information) (1).

3-6

OPERATION EXPLANATION OF COMPONENTS

EMERGENCY CAUTION ITEMS 3

CAUTION

If any of the caution lamps begins to flash, s top the en gine or redu ce the engine speed t o low idling imme­diately and check the trouble spot for necessary actions.

These items must be monitored when the engine is running. If there is any abnormality, the caution lamp for the
location of the abnormality and warn ing la mp ( A) fl ash, and the a larm buzz er so und s inte rmitten tly. Take the nec­essary action immediately.

(1) Engine oil pressure caution lamp (4) Charge filter clogging caution lamp
(2) Engine coolant temperature caution lamp (5) HST charge pressure caution lamp
(3) HST oil temperature caution lamp

ENGINE OIL PRESSURE CAUTION LAMP

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

diately.

REMARK

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

3-7

EXPLANATION OF COMPONENTS OPERATION

ENGINE COOLANT TEMPERATURE CAUTION LAMP

This lamp (2) indicates a raise in the coolant temperature.
When the monitor lamp flashes, run the engine at low idling

speed until green range of the engine coolant temperature
gauge lights.

HST OIL TEMPERATURE CAUTION LAMP

This lamp (3) warns the operator that the HST oil temperature
has gone up.

If it flashes, run the engine at low idling until the HST oil tem­perature gauge indicates the green ra ng e .

CHARGE FILTER CLOGGING CAUTION LAMP

This lamp (4) warns the operator that the HST charge filter is
clogged.

If it flashes, stop the m achine, check for t he ca use of clogg ing,
and replace the filter element with a new part.

HST CHARGE PRESSURE CAUTION LAMP

This lamp (5) warns the operator that the HST charge pressure
has dropped.

If it flashes, stop the machine and check for the cause of the
drop in the charge pressure.

3-8

OPERATION EXPLANATION OF COMPONENTS

CAUTION CAUTION ITEMS 3

CAUTION

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

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

(1) Battery charge circut caution lamp (2) Maintenance caution lamp

BATTERY CHARGE CIRCUIT CAUTION LAMP

This lamp (1) indicates an abnormality in the charging system
while the engine is running.

If the monitor lamp flashes, check the V-belt tension. If any
abnormality is found, see “OTHER TROUBLE (3-125)“.

REMARK

This monitor lamp lights when the ignition switch is turned to
ON immediately after the engine is started or immediately
before the engine is stopped. It does not indicate an abnormal­ity.

3-9

EXPLANATION OF COMPONENTS OPERATION

MAINTENANCE CAUTION LAMP

This lamp (2) lights up for approx. 30 seconds after the starting
switch is turned to the ON position if the filter or oil replacement
interval has been reached.

After replacing the indicated filter or oil displayed on display
panel B (multi-information), reset the interval. For details, see
“METHOD OF USING OIL AND FILTER MAINTENANCE
MODE (3-23)“.

The lamp goes out.

REMARK

At the same time, the filter or oil replacement interval lamp also
lights up or flashes.

3-10

OPERATION EXPLANATION OF COMPONENTS

METER GROUP 3

(1) Engine coolant temperature gauge (6)
(2) HST oil temperature gauge
(3) Fuel level gauge (7) Display panel B (Multi-information)
(4) Engine preheating pilot lamp (8) Reverse travel speed setting switch
(5) Reverse travel speed indicator (9) Shift mode switch

ENGINE COOLANT TEMPERATURE GAUGE
NOTICE

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

Gauge (1) indicates temperature of the engine coolant.
If the temperature is normal during operation , green range ( B)

will light.
If red range (C) lights during operation, move the fuel control

lever to lower engine speed tp approx. 3/4 of the full speed,
and run until the coolant temperature enters green range (B).

If red range (C) lights up during operation , and th e e ngine coo l­ant temperature caution lamp flashes and the alarm buzzer
sounds, stop the machine, run the engine at low idle, and wait
for the coolant temperature to return to green range (B).

Display panel A (Speed range, Set travel speed,
Shift mode Indicator)

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

3-11

EXPLANATION OF COMPONENTS OPERATION

HST OIL TEMPERATURE GAUGE
NOTICE

If the HST oil temperature gauge frequently enters red range (C), che ck for clogging of the oil cooler.

This meter (2) displays the oil t emper atur e in the p ump suc tion
piping.

Green range (B) should be lighted up durin g normal opera­tions.

If red range (C) lights up during operation, move the fuel con­trol lever to lower engine speed to approx. 3/4 of the full spee d,
reduce the load and run until the oil temperature enters green
range (B).

If red range (C) lights up during operation, and the HST oil tem­perature caution lamp flashes and the alarm buzzer sounds,
stop the machine, run the engine at low idle, and wait for the oil
temperature to go down to green range (B).

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

FUEL LEVEL GAUGE

Gauge (3) fuel level in the fuel tank.
During normal operation, the green range (B) should be lighted

up.
If red range (A) lights up during operation, add fuel immedi-

ately. If this is not done, the engin e speed will become irrgula r
or an error display will be shown on the monitor.

(A): Red range
(B): Green range

REMARK

The display is not proportional to the amount of fuel remaining.
If only the red range (A) lights up, there is less than 20 liters of
fuel remaining.

ENGINE PREHEATING PILOT LAMP

hen this lamp (4) is lighted up, it indicates that the electric
heater is being used to preheat the engine.

This lamp lights up when the starting switch is at the HEAT
position.

When the starting switch is released, the lamp will go out.

3-12

OPERATION EXPLANATION OF COMPONENTS

REVERSE TRA VEL SPEED INDICATOR

This indicator (5) displays the travel speed when traveling in reverse.
It is possible to choose the reverse travel speed in five stages according to the nature of the work with out changing

the forward travel speed. This means that the reverse travel speed can be obtained simply by shifting the direc­tional lever. There is no need to shift gear.

If it is desired to raise the efficiency of dozing work, make the reverse travel spee d fa ste r.
When traveling in reverse on rough ground surfaces or when carrying out pushing-up work, make the reverse

travel speed slower.
q There are five settings (A) - (E) for the reverse travel

speed.
The closer the setting is to (A), the slower the reverse

travel speed is in comparison with the forward travel
speed; the closer the setting is to (E), the faster the reverse
travel speed is in comparison with the forward travel
speed.

q When the starting switch is turned from the OFF position to

the ON position, the travel speed is set by default to posi­tion (C).

q Position (B) sets to the same speed a s the forward travel

speed.

q The reverse travel speed is set by turning reverse travel

speed switch (8) to the left or right.
The more it is turned to the right, the faster the set travel

speed becomes.
The more it is turned to the left, the slower the set travel

speed becomes.

3-13

EXPLANATION OF COMPONENTS OPERATION

q Examples of the set travel speed compared with the speed range are shown in the table below.

Speed ranges-

Mode

(A)

(B)

(C)

(D)

(E)

0.2123

0.8 km/h
0

0.8 km/h
0

0.8 km/h
0

0.8 km/h
0

0.8 km/h
0

2.7 km/h

-0.7 km/h

3.4 km/h
0

4.1 km/h

+0.7 km/h

4.8 km/h

+1.4 km/h

5.5 km/h

+2.1 km/h

4.7 km/h

-0.9 km/h

5.6 km/h
0

6.5 km/h

+0.9 km/h

7.4 km/h

+1.8 km/h

8.3 km/h

+2.7 km/h

7.6 km/h

-0.9 km/h

8.5 km/h

8.5 km/h

8.5 km/h

8.5 km/h

Upper line: Reverse set travel speed
Lower line: Difference in reverse travel speed compared with forward travel speed

Reverse travel speed setting table

0

0

0

0

Travel speed (km/h)

Speed range

3-14

OPERATION EXPLANATION OF COMPONENTS

DISPLAY PANEL A (SPEED RANGE, SET TRAVEL SPEED, SHIFT MODE INDICATOR)

This meter (6) indicates speed range, travel speed, and shift mode.
Use the shift mode switch (9) to select the shift mode.
Position (A): Quick shift mode
Pilot lamp (C) on display panel A lights up.
Position (B): Variable shift mode
Pilot lamp (D) on display panel A lights up.

3-15

EXPLANATION OF COMPONENTS OPERATION

QUICK SHIFT MODE

The travel speed is set to the travel speed that matches the general operating load. Operation is easy: each time
the shift switch on the steering, directional, and gearshift lever is pressed, the speed switches 1st ↔ 2nd ↔ 3rd.

q Each time the UP switch on the steering, directional, and

gearshift lever is pressed, the speed switches 1st → 2nd or
2nd → 3rd.

UP

q Each time the DOWN switch on the steering, directional,

and gearshift lever is pressed, the speed switches 3rd →
2nd or 2nd → 1st.

q Direction of travel (E) and speed range (F) are displayed

on the speed range display in the middle.
(E) F: FORWARD
R: REVERSE
N: Neutral
P: Parking lever is at LOCK position
(F) 1: 1st
2: 2nd

3: 3rd
Example: F1 is displayed for FORWARD 1st
q Bar graph (G) around the outside circumference does not light up.

DOWN

q When the starting switch is turned from the OFF position to the ON position, the speed range is set by default

to 1st.

3-16

OPERATION EXPLANATION OF COMPONENTS

VARIABLE SHIFT MODE

The travel speed can be set in 20 stages from 0.8 km/h to 8.5 km/h.
In particular, the minimum travel speed is set low so that work such as loading the machine onto a trailer or travel-

ing over rough places on the road surface can be carried out more safely.
Furthermore, it is possible to select the optimum travel speed over a wider range for work such as plowing or

winch operations.

q Each time the UP switch on the steering, directional, and

gearshift lever is pressed, two segments on the bar graph
around the outside circumference light up and the set
travel speed increases by approx. 0.4 km/h.

q If the UP switch on the steering, directional, and gearshift

lever is kept pressed, the segments on the bar graph
around the outside circumference light up in turn. When
the switch is released, the speed range is set at that posi­tion.

q To reduce the set speed, press the DOWN switch on the

steering, directional, and gearshift lever in the same way.

UP

DOWN

q Direction of travel is displayed at (E) on the speed range

display in the middle and the set travel speed is displayed
on bar graph (G) around the outside circumference.

Nothing is displayed in (F).
(E) F: FORWARD
R: REVERSE
N: Neutral
P: Parking lever is at LOCK position

q When the starting switch is turned from the OFF position to

the ON position, the speed range is set by default to 1st.

q If the mode is shifted from variable shift mode to quick shift

mode, the speed range is set to the nearest speed range
(1st, 2nd, or 3rd).

3-17

EXPLANATION OF COMPONENTS OPERATION

q See the chart below for details of the lighting up of bar gr aph (G) arou nd the out side circumfer ence and the se t

travel speed.

Gauge

No.

1
2

3
4

5
6

7
8

9

10
11

12
13

14

Speed

Set travel

range

0.2 0.8

0.3 1.0

0.5 1.5

0.6 2.0

0.8 2.4

0.9 2.9

1.0 3.4

Speed

Gauge

No.

Speed

range

Set travel

Speed

Gauge

No.

Speed

range

Set travel

Speed

km/h km/h km/h

15
16

17
18

19
20

21
22

23
24

25
26

1.1 3.8

1.3 4.1

1.4 4.5

1.6 4.9

1.8 5.2

2.0 5.6

27
28

29
30

31
32

33
34

35
36

37
38

39
40

2.2 6.0

2.3 6.4

2.4 6.8

2.6 7.3

2.7 7.7

2.9 8.1

3.0 8.5

3-18

OPERATION EXPLANATION OF COMPONENTS

DISPLAY PANEL B (multi-information)

The top and bottom lines in display panel B (multi-information) display information related to the condition of the
machine.

The content of the display is divided into “OPERATING MODE“ and “MAINTENANCE MODE“. Use the buzzer
cancel switch to switch between the operating mo de an d ma in ten a nc e mod e.

For details of switching the mode, see“BUZZER CANCEL SWITCH (3-31)“.

OPERATING MODE (default screen)

Use this mode when operating the machine.

REMARK

When the starting switch is turned from the OFF position to the ON position, display panel B (multi-information)
always displays the operating mode.

The following information is displayed by the operating mode.
Top line (A): Action code
If any abnormality occurs on the machine, an action code is

displayed. If an action code appears, take the applicable
action. For details, see “OTHER TROUBLE (3-125)“.

This displays various types of filter or oil replacement intervals
have been reached.

Bottom line (B): Service meter or engine speed
Use the information switch to switch the display between the service meter and engine speed. For details of

switching the display, see “INFORMATION SWITCH (3-31)“.
Service meter
This displays the total number of hours that the machine has been operated. Use the display to determine the

intervals for periodic maintenance.
While the engine is running, the service meter advances, even if the machine is not being operated.
While the engine is running, the hourglass m a rk a t th e s i de of the me te r lig ht up to sho w th a t th e m et er is ad va nc -

ing.
The meter advances 0.1h for every 6 minutes that the engine is running,

Maintenance mode

This displays various types of information related to mainte­nance of the machine.

For details, see “METHOD OF USING MAINTENANCE MODE
(3-21)“.

3-19

EXPLANATION OF COMPONENTS OPERATION

LAMPS 3

(1) Warning lamp (2) Filter/oil replacement interval lamp

WARNING LAMP

(Red)

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

This lamp (1) flashes when the caution lamp flashes and when
an action code is displayed on display panel B (multi-informa­tion).

When the caution lamp (A) of an emergency warning item
flashes, or when the part of an action code is displayed, the
alarm buzzer sounds continuously at the same time.

FILTER/OIL REPLACEMENT INTERVAL LAMP

(Yellow)
If it is time to replace a filter or change the oil, this lamp (2)

lights up or flashes for approx. 30 seconds after the starting
switch is turned ON.

REMARK

This lamp (2) lights up if there is less than 30 hours remaining
until replacement, and flashes wh en the replacement in terval
has passed.
At the same time, maintenance caution lamp (A) also lights up.

3-20

OPERATION EXPLANATION OF COMPONENTS

After replacing the indicated filter or oil displayed o n display panel B (multi-information), reset the time. For details,
see “METHOD OF USING OIL AND FILTER MAINTENANCE MODE (3-23)“.

The lamp goes out or stops flashing.

METHOD OF USING MAINTENANCE MODE 3

To switch from the operation mode to the maintenance mode,
turn the buzzer switch to the  position and hold it there for at
least 2.5 seconds. The screen will switch to the maintenance
mode.

On the first screen, the oil and filter maintenance mode is dis­played.

EXPLANATION OF MODES AND OPERATION

The maintenance mode has the following 4 sub modes.

Sub mode Function Reference items

Oil/filter maintenance mode

PM clinic auxiliary mode

Fault code display mode

Adjustment mode Adjusts monitor brightness, etc.

Use information switch (1) and buzzer cancel switch (2) to
operate each mode.

Oil or filter replacement time is
displayed

Engine speed or HST oil tempera­ture is displayed

Fault codes for electronic control
related parts are displayed

METHOD OF USING OIL AND FILTER
MAINTENANCE MODE (3-23)

METHOD OF USING PM CLINIC AUXIL­IARY MODE (3-25)

METHOD OF USING FAULT CODE DIS­PLAY MODE (3-26)

METHOD OF USING USER ADJUST
MODE (3-27)

3-21

EXPLANATION OF COMPONENTS OPERATION

METHOD OF SELECTING EACH MODE

Operating mode

(Hold for 2.5 sec)

Oil/filter maintenance mode

Detailed item display

PM clinic auxiliary mode

Detailed item display

Maintenance
mode

Fault code display mode

Detailed item display

Adjustment mode

Detailed item display

(To oil/filter maintenance mode)

3-22

OPERATION EXPLANATION OF COMPONENTS

METHOD OF USING OIL AND FILTER MAINTENANCE MODE
NOTICE

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

In the oil and filter maintenance mode, the replacement inter­vals for oil and filters are displayed on display panel B (multi­information).

(1) The item is displayed.
(2) The time remaining until replacement is displayed.
(3) The quantity of replacements until now is displayed.

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

Replacement interval

Code Display Item

01 ENG OIL Engine oil 500h 500h
02 ENG FILT Engine oil filter 500h 500h
03 FUEL FILT Fuel filter 500h 500h
04 HYD FILT Hydraulic oil filter 2000h 2000h
05 CORR RES Corrosion resistor (*) - ­06 BYPS FILT Bypass filter (*) - ­07 DAMP OIL Damper oil (*) - ­08 FNL OIL Final drive oil 1000h 1000h
09 HYD OIL Hydraulic oil 2000h 2000h
10 POWL OIL Power train oil (*) - -

11 POWL FILT Power train oil filter (*) - -

12 HST FILT HST charge filter 2000h 2000h

q The timing of the 1st interval cannot be changed. If some special condition makes it desirable to change the

1st interval, use the maintenance mode in the operator mode to change the replacement interval as follows.
First, set so that the system thinks that the 1st maintenance has been completed, then set the 2nd and follow­ing times.

q (*) Although the marked item is displayed, it is not used with this machine.

1st time

(cannot be changed)

2nd and following times

(can be changed)

3-23

EXPLANATION OF COMPONENTS OPERATION

When the oil or filter has been replaced, select the applicable
item, then operate the buzzer cancel switch to .

The screen will ask if you want to display the replacement his­tory.

Operate the information switch to select YES, then operate the
buzzer cancel switch to . The replacement quantity will
increase by 1, the replacement interval will be reset, and the
oil, filter change interval lamp will go out.

When this is done, if the maintenance caution lamp does not
go out, there is another item close to the replacement time, so
check that item.

REMARK

To return to the maintenance mode, operate the buzzer cancel
switch to .

3-24

OPERATION EXPLANATION OF COMPONENTS

METHOD OF USING PM CLINIC AUXILIARY MODE

CAUTION

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

The PM clinic auxiliary mode displays the engine speed or hydraulic pressure on display panel B (multi-informa­tion).

Display panel B (Malti-information) displays the item on the top
line (1) and the measured value on the bottom line (2).

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

Display Item Measured value
01-ENG.SPEED Engine speed rpm
02-BATTERY VOLT Battery voltage mV
03-HST TEMP HST oil temperature °C
04-VEHICLE SPEED Vehice speed km/h

REMARK

Items such as the engine speed fluctuate and are difficult to see during the measurement. In such cases, operate
the buzzer cancel switch to . This makes it possible to hold the display of the value.
To cancel this mode, operate the buzzer cancel switch again to .
To return to the maintenance mode, operate the bu zz er canc el switc h to .
When switching the display item of the PM clinic auxiliary mode, set the safety lock lever to the LOCK position. If
the safety lock lever is not at the LOCK position, the display item will not change when the information switch is
operated.

3-25

EXPLANATION OF COMPONENTS OPERATION

METHOD OF USING FAULT CODE DISPLAY MODE
NOTICE

The fault items observed by this function are connected with the electron ic contr ol, so ev en if a fault code
is not displayed, there is probably some problem with the machine. If the operator feels any abnormality
with the machine, the machine should be stopped immediately and checked.

When any disconnection or short circuit in any sensor is detected, the location and fault code are displayed by a 6­digit code on display panel B (multi-infor matio n). When contacting your Komatsu distributor, inform your distributor
of the code at the same time.

If the failure observation function has not determined the condi­tion of the machine, the display is as shown in the diagram on
the right.

With this function, existing failures can be displayed up to a
maximum of 20 items.

If multiple failures are occurring, the display automatically
changes every 2 seconds, so check the code (1).

The display is shown repeatedly.

REMARK

To return to the maintenance mode, operate the buzzer cancel switch to .

3-26

OPERATION EXPLANATION OF COMPONENTS

METHOD OF USING USER ADJUST MODE

With the user adjust mode, the brightness of the panel screen backlighting and the contrast of the liquid crystal
panel can be changed.

1. Adjusting backlighting of liquid crystal display

2. The diagram on the right is the mode for adjusting the
brightness of the backlighting of the liquid crystal panel.

This display will be switched to the screen brightness
adjustment display, if the alarm buzzer cancellation switch
is turned to the  position.

3. The brightness can be adjusted by operating the informa­tion switch.

The higher the number, the brighter the screen becomes;
the lower the number, the darker the screen becomes.

> position: Number increases
< position: Number decreases

4. The brightness of the backlight for the LCD ga uges may be
held constant by turning the alarm buzzer cancellation
switch to the  position.

REMARK

To return to the maintenance mode, operate the bu zz er canc el switc h to .
The brightness of the backlighting of the monitor panel differs according to wheth er the front lamp is lit or not.
Entering this mode when the front lamps are lit makes it possible to adjust the brightness wh en the front lamp s are
lit. In the same way, entering this mode when the front lamps are not lit makes it possible to adjust the brightness
when the front lamps are not lit.

3-27

EXPLANATION OF COMPONENTS OPERATION

5. Adjusting backlighting of display panel B (multi-information)

6. The diagram on the right is the mode for adjusting the
brightness of the backlighting of the dis play panel B (mult i­information).

On the screen, operate the buzzer cancel switch to  to
switch to the screen for adjusting the brightness.

7. The brightness can be adjusted by operating the informa­tion switch.

The higher the number, the brighter the screen becomes;
the lower the number, the darker the screen becomes.

> position: Number increases
< position: Number decreases

8. When the buzzer cancel switch is operated to , the
brightness of the display panel B (multi-information) back­lighting is set.

REMARK

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

3-28

OPERATION EXPLANATION OF COMPONENTS

9. Adjusting contrast of liquid crystal display panel B (multi-information)

10. The diagram on the right is the mode for adjusting the con­trast of the liquid crystal display panel B (multi-information).

On this screen, operate the buzzer cancel switch to  to
switch to the screen to adjust the contrast.

11. The contrast can be adjusted by operating the information
switch.

The higher the number, the deeper the screen becomes;
the lower the number, the lighter the screen becomes.

> position: Number increases
< position: Number decreases

12. When the buzzer cancel switch is operated to , the con­trast of the liquid crystal display panel B (multi-information)
is set.

REMARK

To return to the maintenance mode, operate the bu zz er canc el switc h to .

3-29

EXPLANATION OF COMPONENTS OPERATION

SWITCHES 3

(1) Lamp switch (7) Horn switch
(2) Buzzer cancel switch (8) Room lamp switch (machine equipped with cab)
(3) Information switch (9) Wiper switch (machine equipped with cab)
(4) Reverse travel speed setting switch (10)
(5) Shift mode switch
(6) Starting switch (11) Cigarette lighter (machine equipped with cab)

LAMP SWITCH

This switch (1) lights up when the front and rear lamps, and the
panel lamp light up.

Wiper motor breaker reset button
(machine equipment with cab)

O (OFF) position: Lights out

l (ON) position: Lights on

3-30

OPERATION EXPLANATION OF COMPONENTS

BUZZER CANCEL SWITCH

This switch (2) is used to operate control panel B (multi-information) or to stop the alarm buzzer.
When the switch is released, it returns automatically to the cen-

ter position.

q

When display panel B (multi-information) is in the
operation mode

q When the alarm buzzer is sounding, turn this switch to

the  position to stop the buzzer.

q If the switch is held at the  position for at least 2.5

seconds, the display switches to the maintenance
mode.

q

When display panel B (multi-information) is in the maintenance mode

 position: Cancel or reset to operation mode

 position: Confirms selection or selected item
For details, see “METHOD OF USING MAINTENANCE MODE (3-21)“.

INFORMATION SWITCH

This switch (3) is used to operate display panel B (multi-information).
When the switch is released, it returns automatically to the cen-

ter position.

q

When display panel B (multi-information) is in the
operation mode

turn the switch to < or > to switch the display to service
meter or engine speed.

q

When display panel B (multi-information) is in the
maintenance mode

It is used to move between sub modes, between items, to
move the cursor, or to change values.

For details, see “METHOD OF USING MAINTENANCE
MODE (3-21)“.

REVERSE TRA VEL SPEED SETTING SWITCH

This switch (4) can be used to set the reverse travel speed to a
different setting from the forward travel speed.

For details, see “REVERSE TRAVEL SPEED INDICATOR (3-

13)“.

3-31

EXPLANATION OF COMPONENTS OPERATION

SHIFT MODE SWITCH

Use this switch (5) to switch the shift mode.
For details, see“DISPLAY PANEL A (SPEED RANGE, SET

TRAVEL SPEED, SHIFT MODE INDICATOR) (3-15)“.

STARTING SWITCH

The switch (6) is used to start and stop the engine.
OFF position:
At this position, the starting switch key can be inserted and

removed. When the switch is turned to this position, all the
electric circuits are turned off and the engine stops.

ON position:
In this position, electric current flows in the charging and lamp

circuits.
Keep the starting switch key at the ON position while the

engine is running.

START position:
This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately

after the engine has been started. The key will return to ON position when released.
HEAT position:
When starting the engine in cold weather, set the switch to this position. If the key is kept at the HEAT position, the

engine preheating pilot lamp will light up.
Keep it at the HEAT position for the specified preheating time.
For details, see “STARTING IN COLD WEATHER (3-79)“ in OPERATION portion.

HORN SWITCH

The horn sounds when the bu tton (7) at the r ear of the blade
control lever at the right side of the operator's seat is pressed.

3-32

OPERATION EXPLANATION OF COMPONENTS

ROOM LAMP SWITCH

(Machines equipped with cab)
This switch (8) is used to lights up the room lamp.
OFF position: Lamps are out
ON position: Lamps light up

ON

OFF

WIPER SWITCH

(Machines equipped with cab)
This (9) activates the wipers.
The wiper switches are as follows.

(A) Front window
(B) Rear window

This is also used as the window washer switch.
The switch is operated as follows.
q Window washer only

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

q Wiper only

If this is switched on, the wiper will start.

ON

OFF

ON

OFF

3-33

EXPLANATION OF COMPONENTS OPERATION

q Wiper and window washer

If this is kept pressed to the ON position while the wiper is

ON

working, water will be sprayed out.

OFF

WIPER MOTOR BREAKER RESET BUTTON

(Machines equipped with cab)
This button (10) is the reset button for the rear window wiper.
Use this when the breaker is actuated. When the breaker is

actuated, the button comes out, so push it in to reset.
Position (a): Breaker actuated
Position (b): When normal

REMARK

When the wiper blade is operated, if the blade is held and can­not move for some reason, the breaker is actuated. Remove
the cause of the problem, then press the rese t bu tto n .

CIGARETTE LIGHTER

(Machines equipped with cab)
This (11) is used to light cigarettes.
When the cigarette lighter is pushed in, it will return to its origi-

nal position after a few seconds, so take it out to light your cig­arette.

If the cigarette lighter is remov ed, the so cket can be used as a
power source.

NOTICE
This cigarette lighter is 24V. Do not use it as the power
source for 12V equipment. If it is used so, the equipment
may fail.
The capacity of the cigarette lighter is 120W (24V x 5A).

3-34

OPERATION EXPLANATION OF COMPONENTS

CONTROL LEVERS AND PEDALS 3

(1) Fuel control lever (5) Blade control lever

Joystick (Steering, directional and gear shift

(2)

lever)
(3) Brake pedal (7) parking lever
(4) Decelerator pedal

FUEL CONTROL LEVER

(6) Safety lock lever (for blade control lever)

WARNING

q Check that the steering and forward-reverse selector lever is in the N (neutral) position, when operat-

ing the fuel control lever to the full stroke, while the machine stands.

q When it is necessary to operate the fuel control lever to the full stroke with the steering and forward-

reverse selector lever kept either in the forward or reverse position, operate the fuel control lever
slowly, while paying a full attention to the surroundings for safety.

This lever (1) 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

REMARK

If high-speed travel is not needed and the work consists of
comparatively light loads, return the fuel control lever slightly
from the FULL speed position towards low idling. This
improves the fuel consumption efficiency and also reduces
noise.
For finishing and leveling work or spreading gravel, return the
fuel control lever slightly from the FULL speed position towards
low idling. This reduces shoe slip and increases the service life
of the undercarriage.

3-35

EXPLANATION OF COMPONENTS OPERATION

JOYSTICK (STEERING, DIRECTIONAL AND GEAR SHIFT LEVER)

This lever (2) is used to select the direction of travel, to carry
out steering, and to carry out counterrotation turns.

q

Forward-reverse shifting

Position (a): FORWARD
Position (b): REVERSE
Position N: Neutral
Move to the front to drive forward; move to t he rear to drive in

reverse.

q

Steering

Lever guide

Position (c): LEFT TURN
Position (d): RIGHT TURN
If the lever is at the FORWARD or REVERSE position and it is

operated to the left or right, the machine will turn in the direc­tion that the lever is operated.

If the lever is operated to the left or right to a position where it
becomes heavy, 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.

q Counterrotation turn

When steering the machine, if the lever is operated further from the position where it becomes heavy, the left and
right tracks will rotate in opposite directions and the machine will carry out a counterrotation turn.

q

Gear shifting

Press the shift switch of the knob of the steering, directional,

UP

and gearshift lever to carry out the gearshifting operation.
Press the UP switch to shift up.
Press the DOWN switch to shift down.
When the starting switch is turned to the ON position, the

speed range is set by default to 1st.

For details of the method of selecting the shift mode, monitor
display , and set tr avel speed, see “DISPLAY P ANEL A (SPEED
RANGE, SET TRAVEL SPEED, SHIFT MODE INDICATOR)
(3-15)“.

3-36

DOWN

OPERATION EXPLANATION OF COMPONENTS

If the operating load increases, the travel speed will slowly decrease and the transmission will shift down. When
the load becomes lighter again, the transmission will shift up to the set travel speed.

When the transmission automatically shifts down, the speed range display does not change.

BRAKE PEDAL

WARNING

Do not place your foot on this pedal unnecessarily.

This pedal (3) is used for making emergency stops; do not use
it except in emergencies.

When the pedal is depressed, the parking brake is applied and
the machine stops suddenly.

When traveling on flat ground, use the decelerator pedal to
stop the machine.

DECELERATOR PEDAL

WARNING

q Do not place your foot on this pedal unnecessarily.
q 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.

q When traveling on flat ground, the decelerator pedal can be used to stop the machine. However, this

does not mean that the brake is applied. On slopes, even if the decelerator pedal is depressed and the
engine speed is reduced, the machine may move, so be particularly careful.

q When climbing down a slope, select a gear speed which actuates the engine brake and press the

brake pedal, when necessary.

This pedal (4) is used to lower the engine speed or reduce the
travel speed.

Depress this pedal to reduce the speed when shifting between
forward and reverse or when stopping the machine.

3-37

EXPLANATION OF COMPONENTS OPERATION

BLADE CONTROL LEVER

This lever (5) is used to lift, tilt or angle the blade.
After the engine is stopped, the blade will not move even if the blade control lever is operated.

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 FLOA T 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.
In cold weather, it will take time for the lever to be held at the
HOLD position, so hold the lever by hand at the HOLD position
for at least 1 second.

Raise

TILTING CONTROL

(b) HOLD: Blade is stopped and held in this position.
(e) LEFT TILT
(f) RIGHT TILT

Machine

model

Narrow blade Wide blade

Amount of tilt

mm

D31EX - 330
D31PX 395 435
D37EX - 375
D37PX 395 445
D39EX - 395
D39PX 430 480

Lower

Right tilt

Left tilt

3-38

OPERATION EXPLANATION OF COMPONENTS

ANGLING CONTROL

Turn the knob 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

REMARK

When performing only angling operation, be sure to set the
lever in the neutral (HOLD) position and turn the knob to the
right or left.
If the angling operation is performed while the lever is not in the
neutral (HOLD) position (while either or both of lifting and tilting
operations are performed), all of those operations can be con­tinued, but the moving speed of the blade is lowered. Select
the operations according to the type of the work.
If the lifting or tilting operation is performed while angling oper­ation is performed, the machine moves similarly to the above.

Left angle Right angle

SAFETY LOCK LEVER

(for work equipment control lever)

WARNING

q When leaving the operator's compartment, set the safety lock lever securely to the LOCK position. If

the safety lock lever is not at the LOCK position and the control levers are touched by mistake, it may
lead to serious personal injury.

q If the safety lock lever is not set s ecurely to the LOCK position, the work equipment may move and

cause serious injury. Check that it is in the position shown in the diagram.

q When parking the machine or when carr ying out maint enance, always lower t he work equip ment to the

ground, then set the safety lever to the LOCK position.

This lever (6) is a device to lock the work equipment control
lever.

When it is set to the LOCK position, the movement of the work
equipment is locked.

q The blade control lever can move even when the lever is at

the LOCK position, but the control oil pressure of the blade
control is locked, so the blade does not move.

Free

If the blade control lever is at the FLOAT position and the
safety lever is set to the LOCK position, the blade control lever
is automatically returned to the HOLD position.

REMARK

After the engine is stopped, even if the blade control lever is
operated, the blade will not move. Always lower the blade to
the ground and set the safety lock lever to the LOCK position
before stopping the engine.

Lock

3-39

EXPLANATION OF COMPONENTS OPERATION

PARKING LEVER

WARNING

q When parking the machine, always set the parking lever in the LOCK position.
q If the parking lever is operated, the brake is applied, even when the machine is traveling.

The machine will suddenly stop, so this is dangerous. For this reason, do not operate the parking
lever when the machine is moving, except in emergencies.

This lever (7) is the control lever for the parking brake.

REMARK

If the parking lever is not at the LOCK position when the engine
is started, the limit switch is actuated and the engine will not
start.

Free

Lock

3-40

OPERATION EXPLANATION OF COMPONENTS

FUSE 3

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

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.
q Chassis
Fuse boxes (1) and (2) are installed inside the engine side

cover on the left side.

q Cab (machines equipped with cab)
Fuse box (3) is installed to the rear right of the ceiling.

FUSE CAPACITY AND CIRCUIT NAME

q Chassis
Fuse box (1)

NO.

(A) 20A Head lamp, Rear lamp
(B) 10A Chassis power source, monitor panel
(C) 10A Controller
(D) 10A Horn
(E) 15A Stop solenoid

Fuse

capacity

Name of circuit

3-41

EXPLANATION OF COMPONENTS OPERATION

Fuse box (2)

NO.

(A) 10A Cab power source
(B) 10A (spare)
(C) 15A Canopy heater
(D) 20A Power port
(E) 30A Chassis power source

q Cab (machines equipped with cab)
Fuse box (3) (Machine equipped with cab)

No.

(A) 10A Radio memory
(B) 20A Radio, lamp, cigarette lighter
(C) 10A Rear wiper
(D) 30A Air conditioner
(E) 10A Front wiper

Fuse

capacity

Fuse

capacity

Name of circuit

Name of circuit

ELECTRIC POWER TAKE-OUT ADAPTER 3

NOTICE
q Do not use as a power supply for 12V equipment.

This will cause failure of the equipment.

q When using as a power supply pickup, do not install equipment which exceeds 120W (24V x 5A).

(Machines equipped with cab)
It is possible to remove the cigarette lighter and use the socket as a power supply.
Capacity of cigarette lighter: 120W (24V x 5A)
(Machine not equipment with cab)

1. Open the engine side cover on the right side of the
machine.

2. There is a connector for the power takeoff.
The connector is held securely in position with clamps.

Capacity of each connector:
(1) CN17: 480W (24Vx20A) (Use when the starting switch

is ON)

3-42

OPERATION EXPLANATION OF COMPONENTS

REMARK

Ground the negative wire to the body work or ROPS. Do not ground it to the rubber mounted engine or valves.
This will cause failures.
If the wire is grounded to a point where there is still paint, the electricity will not flow smoothly, so remove the paint.

DOOR - OPEN LOCK 3

(Machines equipped with cab)
Use this when your want to keep the door held open.

1. Push the door against the door catch (1). The door will be
held by the door catch.

2. To release the door , pull lever (2 ) of the door ca tch toward s
the rear of the machine. This will release the catch.

NOTICE
q When keeping the door open, fix it securely to the

catch.

q Always close the door when traveling or carrying out

operations. Leaving the door open will cause the door
to break.

q Keep the door locked open securely. The door may

swing closed because of the vibration.

SASH GLASS INTERMEDIATE LOCK 3

(Machines equipped with cab)
When working with the cab sash glass open, use this lock to

prevent the glass from chattering.
q When the lever is in the FREE position, the glass can be

opened or closed.

q When the lever is moved to the LOCK position, the glass is

fixed in position.

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

Free

Lock

3-43

EXPLANATION OF COMPONENTS OPERATION

CAP, COVER WITH LOCK 3

Use the starting switch key to open and close the caps and
covers.

For their locations , see “LOCKING (3-99)“.
Insert the key as far as it will go to the shoulder. If the key is

turned before it is inserted all the way, it may break.

Shoulder

METHOD OF OPENING AND CLOSING CAP WITH LOCK 3

TO OPEN THE CAP

1. Insert the key into the key slot.

2. Turn the key in the OPEN direction, align the key slot with
the counter mark on the cap, then open the cap.

Match mark

TO LOCK THE CAP

1. Turn the cap until tight, then insert the key into the key slot.

2. Turn the key in the LOCK direction and take out the key.

LOCK

OPEN

Match mark
on the cap

OPEN

LOCK

3-44

OPERATION EXPLANATION OF COMPONENTS

METHOD OF OPENING AND CLOSING COVER WITH LOCK 3

TO OPEN THE COVER (LOCKED COVER)

1. Insert the key into the key slot.

2. Turn the key counterclockwise and open the cover by pull­ing the cover grip.

TO LOCK THE COVER

1. Close the cover and insert the key into the key slot.

2. Turn the key clockwise and take the key out.

OPEN

LOCK

DOOR POCKET 3

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.

(Machines equipped with cab)
These are on the inside of the left and right doors, and can be

used for keeping things or Operation & Maintenance manual.
However, do not put tools or other heavy objects in the pocket.
If the pocket becomes dirty, open the door, lock it in position,

then wash with water. There is a hole to drain the water at the
bottom of the pocket.

3-45

EXPLANATION OF COMPONENTS OPERATION

ASHTRAY 3

(Machines equipped with cab)
This is on the left side of the operator's seat.
Always make sure that you extinguish the cigarette before clos-

ing the lid.

LUNCHBOX HOLDER BELT 3

(If equipped)
This is the place to put your lunchbox.
Hold it in position with the belt.
It can also be used for things other than lunchboxes.

CUP HOLDER 3

(If equipped)
This is the place to put cans or cups.
If drinks are put in places other than the cup holder, the can or

cup will fall over and make the surrounding area or equipment
dirty.

Please make full use of the cup holder.

3-46